Technical Specification

Sabarmati River front development Corporation Page 1 of 117
D-6: GLASS FIBER REINFORCED PLASTIC PIPES, SECTION: D-6 D.6.1 GLASS FIBER REINFORCED PLASTIC PIPES
D.6.1.1 Scope This specification covers requirements for materials, dimensions, classification, testing for pressure and non-pressure pipes made from glass fibre reinforced thermosetting resin with or without on aggregate filler. Specification also covers supplying, lowering, laying, joining and testing Glass-fibre Reinforced Plastic (GRP) pipes at work site used for the conveyance of industrial wastewater of highly acidic and corrosive nature. D.6.1.2 Applicable Codes a) National Standards The manufacturing, testing, supplying, joining and testing at work site of GRP pipes shall comply with all currently applicable statues, regulations, standards and codes. In particular, the following standards unless otherwise specified here in, shall be referred. In all cases, the latest revision of the codes shall be referred to. If requirements of this specification conflicts with the requirements of the codes and standards, this specification shall govern. (i) I.S. 14402 : 1996 Glass fiber reinforced plastics (GRP) pipes, joints and fittings for use for Sewerage, Industrial waste & Water (other than potable)- specification (ii) I.S. 12709 : 1989 Specification for glass fibre reinforced plastics (GRP) pipes for use for water supply and sewerage. (iii) I.S. 6746 : 1972 Unsaturated, polyester resin systems for low pressure fibre reinforced plastics. (iv) I.S. 11273 : 1985 Woven roving fabrics of E glass fibre. (v) I.S. 11320 : 1985 Glass fibre roving for the reinforcement of polyester and of epoxide resin systems. (vi) I.S. 11551 : 1986
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Glass fibre chopped strand mat for the reinforcement of polyester resin systems. b) International Codes Wherever for certain specific requirements the information given in above mentioned IS codes is found to be inadequate, following international codes shall be referred to. However, in case of any discrepancy, decision of Owner / Engineer shall be final and implemented by the Contractor. (i) ASTM D 2412 : W Standard test method for determination of external loading characteristics of plastic pipe by parallel plate loading. (ii) ASTM D 3262 : Standard specification for reinforced plastic mortar sewer pipe. (iii) ASTM D 3517 : Standard specification for glass fibre reinforced thermosetting resin pressure pipe. (iv) ASTM D 3618 : Test for chemical resistance of reinforced thermosetting resin pipe in a deflected condition. (v) ASTM D 3839 : Standard practice for underground installation of flexible thermosetting resin pipe and reinforced plastic mortar pipe. (vi) ASTM D 4161: Standard specification for Fibre glass (glass-fiber reinforced thermosetting resin) pipe joints using flexible elastomeric seals. (vii) ASTM D 477 : Standard specification for elastomeric seals (Gaskets) for joining plastic pipe. (viii) ASNI/AWWA C 950-88 AWWA standard for fiber glass pressure pipe. D.6.1.3 Design and Pressure Rating (a) Design reinforced
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Design of GRP Pipes shall be in accordance with relevant clauses of IS 14402 and ASTM D 3262. The materials sued shall be in accordance with the relevant clauses of IS : 6746, IS 14402, IS : 11320 and IS : 11551 and ASTM D 3262. Other material such as aggregates like graded silica sand, filters, additives and colouring may be used as per specific requirements. (b) Pressure Rating GRP pipes used will be having pressure rating as follows : Pressure class (PN) 3 6 9 12 15 (1 Kpa = 0.102 metres of Water column) Working pressure rating (Pw) (Kpa) 300 600 900 1200 1500
Note : The working pressure rating may be changed for use at fluid temperature greater than 43.5 deg. C in accordance with the manufacturers recommendation. D.6.1.4 Manufacturing (a) General The method of manufacturing of GRP pipes shall be such that the form and the dimensions of the finished pipes are accurate within the limits specified in relevant Clauses of IS : 14402 and ASTM 3262. The surfaces and edges of the pipes shall be well defined and true and shall have squareness of pipe ends as specified in IS : 14402 and ASTM D 3262. The GRP pipes and joints shall be systematically checked for any manufacturing defects by experienced supervisors so as to maintain a high standard of quality. Each pipe should have permanent ISI mark. Owner/Engineer shall at all reasonable times have free access to the place where the pipes and joints are manufactured for the purpose of examining and testing the pipes and joints and of witnessing the test and manufacturing.
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All tests specified either in this specification or in the relevant clauses of Indian Standards or International Standards shall be performed by Supplier/ Contractor at his own cost and in presence of Owner / Engineer if desired. For this, sufficient notice before testing of the pipes shall be given to Owner/ Engineer. If the test is found unsatisfactory, Owner/Engineer may reject any or all pipes of that lot. The decision of Owner/Engineer shall be final and binding on Contractor and not subject to any arbitration or appeal. (b) Dimensions Pipes shall be designated by nominal standard diameters. The nominal diameters, minimum wall thickness, length of barrel, joints etc. shall be within the tolerance limits specified in IS: 14402, ASTM D 3262 and ASTM D 3517. The relevant requirements are specified in Data Sheet A. (c) Workmanship and Finish The inside surface of each pipe shall not have any visible defects such as bulges, dents, ridges foreign inclusion, cracks, crazing, pin holes and bubbles of 1.3 mm and above to the extent that it does not detrimentally affect the performance of the interior surface of the pipe wall. Joint sealing surfaces shall be free of dents, gauges and other surface irregularities that will affect the integrity of the joints. D.6.1.5 Structural Properties (a) Specific initial ring stiffness Each pipe length shall have sufficient strength to withstand the Class AA loading in addition to the over burden of back fill load upto the depth mentioned in data Sheet A above the crown of pipe. The minimum initial ring stiffness for withstanding above load conditions with maximum 5% of long term deflection shall be appropriately determined by manufacturer for actual execution. The stiffness class and minimum wall thickness required are specified in Data Sheet-A. (b) Beam Strength The pipe shall meet or exceed the minimum longitudinal tensile / compressive strength as per relevant clauses of IS: 14402, ASTM D 4262 and ASTM D 3517. (c) Hoop Tensile Strength The pipes shall meet or exceed the minimum hoop tensile strength as per relevant clauses of IS: 14402, ASTM 3262 and ASTM D 3517. D.6.1.6 Hydraulic Properties (a) Soundness
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Each length of pipe including specials shall withstand without leakage of cracking the internal hydrostatic proof pressures as per relevant clauses of IS: 14402, ASTM D 3517. The hydrostatic test pressures are tabulated n Data SheetA. The site test pressure as required is also tabulated in Data SheetA. D.6.1.7 Sampling and Inspection In any consignment all the pipes of same class and size and manufactured under similar conditions of production shall be grouped together to constitute a lot. The conformity of a lot to the requirements of this specification shall be ascertained on the basis of tests on pipes selected from it. Unless otherwise agreed upon between the purchaser and the supplier one lot shall consist of maximum of 100 m of each pressure class, stiffness class and size of pipe produce. Pipes shall be selected at random. In order to ensure randomness, all the pipes in the lot may be arranged in a serial order and starting from any pipe, every r the pipe be selected till the requisite number is obtained, r being the integral part of N/n where N is the lot size and n is the sample size. The scale of sampling shall be as per following table. SCALE OF SAMPLING AND PERMISSIBLE NUMBER OF DEFECTIVES No. of pipes in The lot For Requirements under Clause 1.5 & 1.6 Sample Size Permissible (No. of Pipes) number of defectives (n) 8 13 0 1 Sample size for tests under Clause 1.8 (No. of Pipes) (n) 2 3
(N) Upto 50 51 to 100
Each pipe shall be checked for dimensions, soundness, workmanship finish and deviation from straight. The lot shall be declared as conforming to the requirements of this specification, if the sample pipes taken from the lot meets the requirements of all the tests, otherwise not. Testing GRP pipes manufactured by the above process shall be subjected to the following tests. (a) Testing of pipe at factory
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After selecting pipe specimens randomly from the lot as per clause no. 1.7 above they shall be tested at factory for following tests. (b) Critical dimensions All pipes will be measured for compliance with critical dimensions as specified in relevant clauses of IS : 14407, ASTM D 3262 and ASTM D 3517 after allowing for the specified tolerances. The dimensions shall include diameter, wall thickness, sqareness and length. Pipes not in compliance will be rejected. (c) Visual Acceptance Generally the pipe shall be free from all defects, including de-laminations, bubbles, pinholes, cracks, pits, blisters, foreign inclusions and resin-starved areas that due to their nature, degree or extent, detrimentally affect the strength and serviceability of the pipe. The pipe shall be as uniform as commercially practicable in colour, capacity, density and other physical properties. (d) Tests for Specific Initial Ring Stiffness (SIRS) Pipe ring samples shall be taken as per 4.6.2 from each diameter manufactured and tested for SIRS as per relevant clauses of IS : 14407, ASTM D 2412 and ASTM D 3517. If a pipe sample from a lot fails to met the required stiffness, a further two samples shall be tested from that lot. If they both pass, the lot will be accepted. If they fail Pipes will be tested on an individual basis and only pipes which pass will be accepted. (e) Hydrostatic Soundness Test The manufacturer shall hydrostatically test pipes by hydrostatic proof test in accordance with the relevant Clause of IS : 14407 and ASTM D-3517. The procedure should be as follows : Each length of pipe, shall be placed in a hydrostatic pressure test machine which seals the ends and exert no end loads. The pipe shall be filled with water, expelling all air and an internal water pressure shall be applied at a uniform rate not to exceed 300 Kpa/S until the test pressure of two times the pressure class is reached. This pressure shall be maintained for one minute. The pipe shall show no visual signs of weeping leakage or fracture of the structural wall. Integral bells, including reinforcement sleeves, if any, or affixed coupling shall be tested with the pipe. Any pipes failing to pass this test will be rejected. Rejected pipes may be repaired and retested, if they pass, they will then be accepted. (f) Beam Strength Test The manufacturer shall test the pipe for longitudinal tensile strength as per the relevant clauses in IS : 14407, ASTM D 2412, ASTM D 3262 and ASTM D
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3517. The sample size shall be selected as per clause 1.7 above. If may sample should fail to meet the requisite value specified in the IS/ASTM codes, five (5) further samples should betaken and tested. If the results comply with requirement, all pipes will then be acceptable. However, if these five samples fail then all pipes from that lot will be rejected unless individually proven acceptable. (g) Hoop Tensile Strength The manufacturer shall test the pipe for hoop tensile strength as per relevant clauses in IS : 14407, ASTM D 3262, ASTM D 3517. The sample size shall be selected as per clause no. 1.7 above. Every sample piece should meet or exceed the hoop tensile strength specified in IS : ASTM codes. If any sample fails to meet the requisite value five (5) further samples shall be taken and tested. IF the results comply with requirement, all pipes will then be acceptable. However, if these five samples fail then all pipes from that lot will be rejected unless individually proven acceptable. Rejected pipes will, however, be acceptable for use at a lower working pressure as per the criteria stated in the specification. (h) Long Term Hydrostatic Strain Test The pressure as classes as given in relevant clause shall be based on long term hydrostatic design pressure data obtained as per relevant clauses of IS : 14407, ASTM D 3262 and ASTM D 3517. For those products where no previous long term hydrostatic testing has been performed on similar products the full type testing shall be carried out to define design pressure classes based on extrapolated strengths at 50 years. When a hydrostatic design basis has already been established for a nominally similar pipe using the same manufacturing process, the manufacturer need only conduct the re-qualification test as described in the relevant clauses of IS : 12709. (i) Test Certificate for Chemical resistance of GRP Pipes in a deflected Condition The manufacturer / supplier / contractor shall produce a test certificate for chemical resistance of GRP pipes in a deflected condition that when installed within 5% deflection the pipes will last over 60 years under highly acidic and corrosive condition and stand guarantee for the same. For waste water characteristics the relevant reports / documents available with owner shall be referred, if required. D.6.1.8 Marking Both ends of each length of pipe and fitting shall be marked at least in letters not less than 12 mm in height and of bold type style in a colour and type that remains legible under normal handling and installation procedures. The marking shall include the following : (a) Internal diameter
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(b) (c) (d) (e)
Class of pipe (pressure and stiffness) Date of manufacture Name of manufacturer or his registered trade mark or both Nominal thickness
All pipes and fittings shall have ISI mark. D.6.1.9 Handling The manufacturer / Supplier (M/S) shall be responsible for safe delivery of pipes and fittings as per order place and as per the schedule. If the contractor for works is other than manufacturer / supplier, then M/s shall submit a complete manual of instruction/ guide./ procedure for handling of pipe before installation. Broadly following instructions/ procedures shall be followed. D.6.1.10 Fire Safety GRP pipes manufactured using petrochemicals and are inflammable. Hence manufacturer/supplier/contractor (m/s/c) shall take utmost precaution while handling, transporting, storing, loading/unloading, installing, and testing, etc. at all stages, against fire hazard. Care must be taken to avoid exposure of the pipe to welders sparks, cutting-torch flames or other heat / flame / electrical sources which could ignite the pipe material. D.6.1.11 Transportation All pipe sections shall be supported on flat timbers spaced on a maximum of 4 meters centres with a maximum overhand of 2 metres in trucks. No pipes shall be in contact with other pipes while transportation. Maximum stack height will be approximately 2 meters. Pipes shall be strapped to the vehicle over the support points using pliable straps or ropes, Steel cables or chains shall not be allowed for strapping without adequate padding, stacking pipes shall limit the deflection as follows: 3.0% o9f diameter for stiffness class SN 1250. 2.5% of diameter for stiffness class SN 2500 2.0% of diameter for stiffness class SN 5000 1.5% of diameter for stiffness class SN 10000 D.6.1.12 Storing Pipes may be stored on ground or on flat timbers. When storing on ground the ground shall be flattened and made free of potential damaging debris. All pipes shall be choked to prevent rolling. If it is necessary to stack pipes, flat timber supports at maximum 6 metre spacing with chocks shall be used. If it is available, the original shipping dunnage shall be used. The stacks shall be stable against wind or other horizontal forces. Maximum stack height allowable shall be approximately 2 metres. Pipes larger than 1400 mm diameter shall not be stacked. The permissible deflection shall be as per clause 1.15.
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Rubber ring gasket shall be shipped separately from the couplings and shall be stored in the shade in their original packaging and shall not be exposed to sunlight except during utilisation. The gaskets shall also be protected from exposure to greases and oils which are petroleum derivatives and from solvents and other deleterious substances. Gasket lubricant shall be carefully stored to prevent damage to the container. Partially used buckets shall be prevented from contamination of the lubricant. D.6.1.13 Unloading, lifting and lowering Adequate control shall be ensured during unloading and lifting of pipes with guide ropes attached to pipes or packages. Spreader bars shall be sued when multiple locations are necessary. The pipes shall not be dropped to avoid impact or bump, particularly at pipe ends. Non-utilised stack of pipes shall not be handled a single bundle. Non-utilised pipes shall be handled separately, one at a time. Pipes shall be handled or lifted with pliable straps, slings or ropes. Steel cables or ropes shall not be used for lifting and transportation of pipe. Ropes shall not pass through the section of pipe, end to end. If any time during handling or installation of pipe, any damage, such as gouge, crack or fracture occurs, the pipe shall be repaired or replaced as directed by Owner / Engineer before installation. D.6.1.14 Jointing Pipes Pipe sections shall be jointed utilising double bell couplings and shall be assembled as indicated in the following paragraphs and as per the relevant clauses of ASTM D 3517, STM D 4161. The gasket used for jointing purpose shall be as per ASTM F 447, specification for Elastomeric Seals (gasket) for joining plastic pipes. (a) Clean Coupling Double bell coupling grooves and rubber gasket ring shall be thoroughly cleaned to make sure no dirt or oil is present. (b) Install Gaskets The gasket shall be inserted into the grooves, leaving two to four uniform loops of rubber extending out of the groove. There should be a minimum of one loop for each 450 mm of gasket ring circumference. (c) Lubricate Gaskets Uniform pressure shall be applied to push each loop of the rubber gasket into the gasket groove. Then using a clean cloth, a thin film of lubricant shall be applied to the rubber gasket. Normal amount of lubricant consumed per joint shall be as follows :
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600 - 800 mm dia. 900 - 1000 mm dia. 1100 - 1200 mm dia. 1300 - 1400 mm dia. 1500 - 1600 mm dia. 1800 mm dia. (d) Clean and Lubricate Spigots
0.1 Kg 0.15 Kg 0.20 Kg 0.25 Kg 0.30 Kg 0.35 Kg
Pipe spigots shall be thoroughly cleaned to remove any dirt, grit, grease, etc. Using a clean cloth, a thin film of lubricant shall be applied to the spigots from the end of the pipe to the black positioning stripe. (e) Fixing of Clamps The first clamp is fixed anywhere on first pipe or left in position from previous joint. The second clamp is to be fixed on the pipe to be connected in the correct position relative to the alignment stripe on the spigot end so as also to act as a stopper. Clamp contact with the pipe shall be padded or otherwise protected to prevent damage to the pipe and have high friction resistance with the pipe surface. Care shall be taken in the alignment of the coupling. (f) Pipe Placement The pipe to be connected shall be placed on the bed with sufficient distance from the previously joined pipe to allow lowering the coupling into position. (g) Join Coupling Come along jacks shall be installed to connect the pipe clamps and two 10 cm x 10 cm timbers or similar (large diameters may require a bulkhead) are placed between the pipe previously connected and the coupling. While these are held in position, the new pipe shall be entered into the coupling until it rests against the second pipe clamp. Come-along jack might need protective plank in order not to rub against the pipe. (h) Join Pipes Come along jacks shall be loosened and the timbers removed before retightening the jacks for entering the coupling onto the previously connected pipe. Correct position of the edge of the coupling to the alignment stripe home line shall be checked. (i) Angular Deflection Maximum angular deflection (turn) at each coupling joint shall not exceed the amounts given below. Also the pipes should be joined in straight alignment and thereafter deflected angularly if necessary.
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Nominal Angular Deflection at Double Bell Coupling Joint Pipe diameter (mm) 300 to 600 700 to 800 900 to 1000 1100 to 1300 1400 to 1600 1800 to 2400 (j) Layup Joints The manufacturer / tenderer shall provide full details of the layup joints and polymer resin which will be used for connection of pipes to manholes. (k) Joining pipes with different wall thickness When two pipes of same diameter but of different wall thickness are required to be joined at site, the contractor is required to execute the joint very precisely so as to have straight alignment of pipe inverts. Nom. Angular deflection (Degrees) 3.0 2.5 2.0 1.5 1.25 1.00 Nom. Offset (mm) Section Lengths 3m 6 m 12 m 157 314 628 131 262 523 105 209 419 79 157 314 65 131 262 52 105 209 Nom. Radius of Curvature (m) Section Length 3m 6m 12 m 57 115 229 69 137 275 86 172 344 115 229 458 138 275 550 172 344 688
D.6.1.15
Pipe Bedding and Backfilling (a) Pipe Bedding The pipe bedding zone starts from the bottom of trench to the invert level of pipe. This depth varies with pipe diameter but shall be a minimum of 150 mm thick layer of granular material not greater than 10 mm in size. Pipe bedding material shall be sand or gravel as per the requirements of the backfill materials and the same as that utilized for select material in the remainder of the pipe zone. The bedding shall be compacted to a minimum 90% Standard Proctor Density (70% of maximum relative density for crushed rock, crushed stone and gravels). The finished bed shall be plane. The minimum depth shall be 1/4th the diameter (minimum 150 mm) and shall provide uniform and continuous support for the pipe. Prior to pipe placement, the compacted bed shall be slightly loosened at the invert location to a depth 25 to 50 mm so the pipe, when positioned into the trench, will seat well into the bed. The bed shall be over excavated at each coupling (joint) location to ensure that the pipe will have continuous support. The pipe shall not rest on the coupling for support. However,
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it shall be assured that the coupling area is properly bedded and backfilled after the joint assembly is completed. (b) Backfilling Pipe Backfilling shall be done immediately after joining pipes. Proper selection, placement and compaction of pipe zone backfill shall be ensured to control the vertical deflection. Installed pipes shall have initial deflection less than the values to be given by the tenderer depending on the type of soil to encountered with, the pipes shall have no bulges, flat areas, or other abrupt changes of curvature. (c) Pipe Zone Backfill Pipe zone for backfilling shall be defined as the zone from the bed upto 300 mm above the pipe crown. Most coarse grained soils are acceptable. This shall be composed of gravel or clean sand. However, silty sand, clayey sand, silty gravel and clayey gravel shall not be used unless proposed to be used in conjunction with gravel or clean sand. The selection of backfill material would require the approval of the Engineer-incharge. Compatibility of the backfill material and the native soil shall be checked. Sieve analysis shall be carried out at selected sections to ensure that between two adjacent soils D85 finer is grater than 0.2 D15 coarser where D85 percentile size of finer soil and D15 is the 15 percentile size of coarser soil. Where native soil is shown in the pipe zone the soil shall be granular, free of debris and organic materials and rocks and soil clumps grater than 2 times the maximum gravel size. Maximum size of grain for the backfill material shall be : Upto 1600 mm dia. 19 mm For 1800 mm to 2400 mm dia. 25 mm Backfill shall not be onto the pipe from the top of the trench. During backfilling, it shall be made certain that the granular material flows completely under the pipe to provide full support. A board or other blunt toll may be used to push and compact the backfill under the pipe. Proper completion of this step is a very important phase of backfilling the pipe. Proper backfilling shall be done in 150 mm to 300 mm lifts, depending on backfill material and compaction method. Between each lift. The proper compaction shall be attained to ensure that the pipe will have adequate side support. Compaction of sandy (Vs. Gravel) backfill is accomplished most easily when the material is at or near its optimum moisture content. When backfilling reaches pipe spring line (half of diameter), all compaction shall be done first near the trench sides and proceed towards the centre.
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Initial vertical ovalization shall not exceed 3% of diameter. This measurement shall be determined when backfilling reaches pipe crown. All lifts with a specified density must be properly compacted. Care must be taken to avoid excessive compactive effort above the pipe crown, to avoid bulges or flat areas, however, the material in this area shall not be left loose. D.6.1.16 Alternate Installations When the combination of pipe stiffness, cover depth, and native soil characteristics places the installation required in the alternate category, following options are available. 1) Use a higher stiffness pipe to permit a standard installation. 2) Increase the trench width The specific requirement for standard and alternate installation are given in Data Sheet A. D.6.1.17 Unstable Trench Bottom Where the trench bottom has soft, loose, or highly expansive soils, the trench bottom shall be regarded as unstable. An unstable trench bottom shall be stabilised before laying pipe, or a foundation must be constructed to minimise differential settlement of the trench bottom. The engineer-in-charge may elect, depending upon the severity of the unstable soil, to require special foundations by stabilisation of the bottom material; or by over excavation and replacement with a foundation and bedding of processed gravel, suitably grades, and impervious to infiltration or migration of the unstable soil. The depth of the stone or gravel material used for foundation will depend upon the severity of the trench bottom soil conditions, but shall be a minimum of 150 mm. the normal bedding shall be placed on top of any foundations. Foundations and bedding materials shall be selected to avoid migration of one into the other that could cause loss of pipe bottom. Additionally, the maximum allowable pipe section length between flexible joints shall be 6 meters. D.6.1.18 Flooded Trench When the ground water table is above the trench bottom, the water level shall be lowered to at least the trench bottom (preferably about 200 mm below) prior to preparation of the pipe bed. If the water level can not be maintained below the top of the bedding, special installation methods shall be adopted at no extra cost to achieve proper pipe support. Specification of an appropriate procedure shall require the approval of Engineer-in-charge. If the pipe is empty in a flooded trench, a minimum cover of one pipe diameter of dense soil (1,900 kg/cu.m. or more) will be normally sufficient to prevent pipe flotation. D.6.1.19 Dewatering the Trench The following cautions shall be taken when dewatering
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Avoid pumping long distances through the backfill materials or native soils, which could cause loss of support to previously installed pipes due to removal of material or migration of soil. Do not turn off the dewatering system until sufficient cover depth has been reached to prevent pipe flotation.
D.6.1.20
Use of Temporary Trench Shoring If at all possible the use of trench shoring or sheeting at pipe level should be avoided. In case where shoring or sheeting are necessary and can not be avoided, the following requirements must be met : (a) Alternative 1 Install the shoring to a depth of 300 mm above the top of the pipe, leaving the native trench sides fully exposed at pipe level. (b) Alternative 2 Use sheeting which will last the life of the pipeline, and leave the sheeting permanently in position. (The sheeting may be cut off 300 mm above top of pipe and the upper sections extracted, is so desired). Native Soil Classification & Allowable Initial Deflection Soil Group Cohesive Granular Blow Count Allowable initial installed deflection of % Diameter 1 Hard & Very Stiff Very Dense & Dense 30 3.0 2 Stiff Medium 16-30 3.0 3 Medium Loose 6-15 2.5 4 Soft Very Loose 3-5 2.0
Checking to insure that the above initial requirements MUST be done for each pipe immediately after completion of installation (typical within 24 hours after reaching maximum cover). While initial deflection in Table above area acceptable for pipe performance, a value more than 2% indicates the installation intended has not been achieved and shall be improved for future pipes (i.e. increased pipe zone backfill compaction, coarser grained pipe zone backfill materials, or wider trench etc. Following procedure shall be adopted for checking the initial diametrical deflection for installed pipes : Complete backfilling shall be done to require grade. The temporary sheeting (if used) shall be completely removed.
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The dewatering system (if used) shall be turned off. The pipes vertical diameter shall be measured and recorded. Note : For small diameter pipes, a VEROC delfectometer or similar device may be pulled through the pipes to measure the vertical diameter. The vertical deflection shall be calculated as follows :% deflection = Actual I. D. Installed Vertical I. D. Actual ID x 100
Compare deflections to acceptable values as defined in Clause 8.1. Deflection checks shall be done when the first installed pipes have been backfilled to grade and continued periodically throughout the entire project. Laying shall not get too far ahead before verifying the installation quality. This will ensure early detection and correction of inadequate installation methods and keep to a minimum the number of inadequately installed pipes. Pipes installed with initial deflections exceeding the values in Clause 8.1 shall be reinstalled so the initial deflection is less than those values. Clause 8.4 Correcting Over Deflected Pipe, for limitations applicable to this work shall be followed. Actual I. D. may be verified or determined by measuring the diameters of a pipe laying loose (no pipes stacked above) on a reasonable plane surface, as follows. Actual I. D. = Vertical I. D. + Horizontal I. D. 2 OR I. D. (1) + I. D. (2) 2
Actual D.6.1.21
I. D.
Correcting Overdeflected Pipe Pipes installed with initial diametrical deflections exceeding the values in Clause 1.22 shall be corrected to ensure the long term performance of the pipe. (a) For Pipe Deflected upto 8% of Diameter : Excavate to near the pipe invert / haunch depth. Excavation just above and at the sides of the pipe should be done utilizing hand tools to avoid impacting the pipe with heavy equipment. Inspect the pipe for damages. Damaged pipe should be repaired or replaced as directed by the Owner / Engineer. Re-compact haunch backfill, ensuring it is not contaminated with the native soil.
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Re-backfill the pipe zone in lifts with the appropriate material, compacting each layer ad required by the cover depth to limit the pipe deflection. Backfill to grade and check the pipe deflections to verify they have not exceeded the values in Clause 8.1. (b) For Pipe Deflected Greater than 8% Pipe Diameter Pipes over 8% deflections shall be replaced completely. No attempt to jack or wedge the installed over-deflected pipe into a round condition shall be made to avoid damage to the pipe. D.6.1.22 Field Hydro Testing for Water Tightness Completed pipeline inclusive of manholes shall be hydrostatically tested for water tightness prior to acceptance and service. It shall be done regularly as installation proceeds. Installation should never exceed testing by more than 1 Km. After the joints have thoroughly set and have been checked by Owner / Engineer and before backfilling the trenches the entire section of laid pipeline shall be tested for water tightness by filling in pipes with water to the level of 1.5 M above the top of the highest pipe in the stretch. The heading of water shall be retained for 1.0 hour. If any leakage is detected it shall be repaired and retested for no leak. IF required by Owner / Engineers, the contractor shall dewater the excavated pit / trench and keep id dry during the period of testing. The testing of manholes for water tightness shall be carried out by complete filing of the manhole with water and the loss of water shall not exceed 2.0 lit / hr / m height of manhole. All equipment for testing at work site shall be supplied and erected by Contractor. Water for testing of pipeline shall be arranged by Contractor. Damage during testing shall be contractors responsibility and shall be rectified by him to the full satisfaction of Owner / Engineer. Water used for the test shall be removed form the pipes and not released to the excavated trenches. D.6.1.23 Concrete Encasement When encasement of pipes in concrete has been specified to carry unusual loads, specific limitations in the installation procedures shall be observed.The concrete surround must be placed stages allowing sufficient time layers for the cement to set (no longer exert buoyant forces). Maximum lift height is variable with nominal pipe stiffness as shown below :
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SN 1250 & SN 2500 SN 5000 SN 10000 D.6.1.24 Measurement
- Not more than 300 mm or D/4 whichever is larger - Not more than 450 mm or D/3 whichever is larger - Not more than 600 mm or D/2 whichever is larger
All GRP pipes shall be measured according to the work actually done and no allowance will be made for any waste in cutting to the exact length required. The measurement for pipes shall be in running meters nearest to a centimeter of length along the centre line of pipe as actually laid at work site. The rate for providing, lowering, laying and jointing of GRP pipes and fittings shall be deemed to include cost of joining material such as couplings, gaskets, lubricants, equipment and tools for making joints, testing as specified and as directed and the extra excavation required for bedding of pipes and fittings / couplings etc. DATA SHEET A (1) (2) (3) (4) (5) (6) Pressure Class required Working pressure rating Hydrostatic test pressure Site test pressure Length of barrel or each pipe length Stiffness class and depth of cover Stiffness Class D (7) Minimum wall thickness stiffness KPA. 248 : 30 mm : : : : : : PN 6 Bar 6 kPa = 61.2 m wc 12 kPa = 122.4 m wc As per Clause 1.24 12.0 m Maximum depth of cover m 12
(8) Joints The GRP pipes shall be joined by utilizing Double Bell Couplings. In special cases as per the manufacturer / suppliers instructions the following types of joints may be allowed by Owner / Engineer. a) Flexible steel coupling with anyone of i) Epoxy or PVC coated steel mantle ii) Stainless steel mantle, or
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iii) b) c)
Hot dip galvanised steel mantle
Mechanical steel couplings and/or Lay-up joints
(9) Width of trench (Bt) from the invert level of pipe upto ground level above the top of pipe. Width of trench shall be as per drawing given in tender document. (11)Bedding and backfilling for pipes: As per Clause 1.16.
D.6.5
CONNECTION WITH EXISTING TRUNKS
D.6.5.1 It will be necessary to give connections of the new 2000 mm dia. GRP pipes with Existing manhole near Ambedkar Bridge East side near pumping station.The connection will be made with all jointing materials etc. complete. The payment will be made on item completed as stated above.
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Specification for installing Glass Fiber Reinforced Plastics (GRP) pipes 2901. SCOPE This work shall consist of furnishing and installing Glass Fiber Reinforced Plastics (GRP) pipes, Joints and Fittings for use for sewerage, industrial Waste and water other than portable water conforming to IS 14402-1966 of the type, diameter and length required at the locations shown on the drawings or as ordered by the Engineer and in accordance with the requirements of these Specifications. 2902. MATERIALS All materials used in the manufacturing and laying of pipes shall conform to Glass Fiber Reinforced Plastics (GRP) pipes, Joints and Fittings for use for sewerage, industrial Waste and water other than portable water conforming to IS 14402-1966 Each consignment of GRP pipes shall be inspected, tested, if necessary, and approved by the Engineer either at the place of manufacture or at the site before their incorporation in the works. 2903. EXCAVATION FOR PIPE The foundation bed for laying of pipes shall be excavated true to the lines and grades shown on the drawings or as directed by the Engineer. The pipes shall be placed in shallow excavation of the natural ground or in open trenches cut in existing embankments, taken down to levels as shown on the drawings. In case of high embankments where the height of fill is more than three times the external diameter of the pipe, the embankment shall first be built to an elevation above the top of the pipe equal to the external diameter of the pipe, and to width on each side of the pipe of not less than five times the diameter of pipe, after which a trench shall be excavated and the pipe shall be laid. Where trenching is involved, its width on either side of the pipe shall be a minimum of 150 mm or one-fourth of the diameter of the pipe whichever is more and shall not be more than one-third the diameter of the pipe. The sides of the trench shall be as nearly vertical as possible. The pipe shall be placed where the ground for the foundation is reasonably firm. Installation of pipes under existing Drain, structure or culverts shall be avoided as far as possible. When during excavation the material encountered is soft, spongy or other unstable soil, and unless other special construction methods are called for on the drawings or in special provisions, such unsuitable material shall be removed to such depth, width and length as directed by the Engineer. The excavation shall then be backfilled with approved granular material which shall be properly shaped and thoroughly compacted up to the specified level. Where bed-rock or boulder strata are encountered, excavation shall be taken down to atleast 200 mm below the bottom level of the pipe with prior permission of the Engineer and all rock/boulders in this area be removed and the space filled with approved earth, free from stone or fragmented material, shaped to the requirements and thoroughly compacted to provide adequate support for the pipe.
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Trenches shall be kept free from water until the pipes are installed and the joints have hardened. 2904. BEDDING FOR PIPE The bedding surface shall provide a firm foundation of uniform density throughout the length of the pipe, shall conform to the specified levels and grade, and shall be as specified here: First Class bedding: Under first class bedding, the pipe shall be evenly bedded on a continuous layer of well compacted approved granular material, shaped concentrically to fit the lower part of the pipe exterior for atleast ten per cent of its overall height or as otherwise shown on the drawings. The bedding material shall be well graded sand or another granular material passing 5.6 mm sieve suitably compacted/rammed. The compacted thickness of the bedding layer shall be as shown on the drawings and in no case shall it be less than 75 mm. 2905. LAYING OF PIPE No pipe shall be laid in position until the foundation has been approved by the Engineer. Where two or more pipes are to be laid adjacent to each other, they shall be separated by a distance equal to at least half the diameter of the pipe subject to a minimum of 450 mm. The arrangement for lifting, loading and unloading concrete pipes from factory/yard and at site shall be such that the pipes do not suffer any undue structural strain, any damage due to fall or impact. The arrangement may be got approved by the Engineer. Similarly, the arrangement for lowering the pipe in the bed shall be got approved by the Engineer. It may be with tripod-pulley arrangement or simply by manual labour in a manner that the pipe is placed in the proper position without damage. The laying of pipes on the prepared foundation shall start from the outlet and proceed towards the inlet and be completed to the specified lines and grades. In case of use of pipes with bell-mouth, the belled end shall face upstream. The pipes shall be fitted and matched so that when laid in work, they form a uniform gradient with a smooth uniform invert. Any pipe found defective or damaged during laying shall be removed at the cost of the Contractor. 2906. JOINTING The pipes shall be jointed either by collar joint or socket spigot joint. In the former case, the collars shall conform to IS 14402-1966 and having the same strength as the pipes to be jointed. Jointing and Gluing space shall conform to various standards laid in Indian standard as well as British standards according to the diameter of the pipe For jointing pipe lines under light hydraulic pressure, the recess at the end of the pipe shall be filled with suitable approved compound. Pipes shall be so jointed that the ring of one pipe shall set into the recess of the next pipe.The ring shall be thoroughly compressed by jacking or by any other suitable method.
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All joints shall be made with care so that their interior surface is smooth and consistent with the interior surface of the pipes. After finishing, the joint shall be kept covered and damp for at least four days. 2907. BACKFILLING Trenches shall be backfilled immediately after the pipes have been laid and the jointing material has set. The backfill soil shall be clean, free from boulders, large roots, excessive amounts of sods or other vegetable matter, and lumps and shall be approved by the Engineer. Backfilling up to 300 mm above the top of the pipe shall be carefully done with approved graded gravelly material and the soil thoroughly rammed, tamped or vibrated in layers not exceeding 300 mm, particular care being taken to thoroughly consolidate the materials under the haunches of the pipe. Approved pneumatic or light mechanical tamping equipment can be used. Filling of the trench shall be carried out simultaneously on both sides of the pipe in such a manner that unequal pressures do not occur. In case of high embankment, after filling the trench up to the top of the pipe in the above said manner, a loose fill of a depth equal to external diameter of the pipe shall be placed over the pipe before further layers are added and compacted. 2908. MANHOLES AND OTHER ANCILLARY WORKS Manholes and other ancillary works shall be constructed in accordance with the details shown on the drawings or as directed by the Engineer. 2909. OPENING TO TRAFFIC No traffic shall be permitted to cross the pipe line unless height of filling above the top of the pipe line is at least 1200 mm. 2910. MEASUREMENTS FOR PAYMENT Glass Fiber Reinforced Plastics (GRP) pipes shall be measured along their centre between the inlet and outlet ends in linear meters. Selected granular material for pipe bedding shall be measured as laid in cubic meters. Ancillary works like Construction of manholes etc., shall be measured as provided for under the respective Sections. 2911. RATE The Contract unit rate for the installing Glass Fiber Reinforced Plastics (GRP) pipes shall include the cost of pipes including loading, unloading, hauling, handling, storing, laying in position and jointing complete and all incidental costs to complete the work as per these Specifications. Ancillary works such as excavation including dewatering & backfilling, concrete and masonry shall be paid for separately, as provided under the respective Clauses.
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Detailed Technical Specifications for FRP Manholes The FRP Manholes Shall be constructed, tested and installed as per the Standards/method mentioned in the attached sheets and drawings. The wall thickness will be as per the drawing attached. Manhole shall be able to withstand the load of heavy trucks as they are to be laid below the road having heavy traffic. Contractor has to give guarantee for that. Proper base to receive the prefabricated manhole shall be prepared by the contractor as the instructions given in the sheet. The joints of pipes and manholes shall be made leak proof using resins and fibers .The resin and fiber shall be sustainable to industrial effluent. The effluent standards are given in Annexure-A. Required Concrete work shall be done on top of manhole to fix the manhole seat and cover and match with existing ground level/road level.
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304. EXCAVATION FOR LAYING PIPES 304.1. Scope Excavation for pipe laying shall consist of the removal of material for the laying pipe and Manholes & other similar structures, in accordance with the requirements of these Specifications and the lines and dimensions shown on the drawings or as indicated by the Engineer. The work shall include construction of the necessary cofferdams and cribs and their subsequent removal; all necessary sheeting, shoring, bracing, draining and pumping; the removal of all logs, stumps, grubs and other deleterious matter and obstructions, necessary for laying pipes, placing the foundations; trimming bottoms of excavations; backfilling and clearing up the site and the disposal of all surplus material. 304.2. Classification of Excavation 301.2. All materials involved in excavation shall be classified in accordance with Clause 304.3 Construction Operations 304.3.1 Setting out: After the site has been cleared according to Clause 201, the limits of excavation shall be set out true to lines, curves and slopes to Clause 301.3.1. 304.3.2.Excavation: Excavation shall be taken to the width of the lowest step of the footing and the sides shall be left plumb where the nature of soil allows it. Where the nature of soil or the depth of the trench and season of the year do not permit vertical sides, the Contractor at his own expense shall put up necessary shoring, strutting and planking or cut slopes to a safer angle or both with due regard to the safety of personnel and works and to the satisfaction of the Engineer. The depth to which the excavation is to be carried out shall be as shown on the drawings, unless the type of material encountered is such as to require changes, in which case the depth shall be as ordered by the Engineer. Propping shall be undertaken when any foundation or stressed zone from an adjoining structure is within a line of 1 vertical to 2 horizontal from the bottom of the excavation. Where blasting is to be resorted to, the same shall be carried out in accordance with Clause 302 and all precautions indicated therein observed. Where blasting is likely to endanger adjoining foundations or other structures, necessary precautions such as controlled blasting, providing rubber mat cover to prevent flying of debris etc. shall be taken to prevent any damage. 304.3.3 Dewatering and protection: Normally, open foundations shall be laid dry. Where water is met with in excavation due to stream flow, seepage, springs, rain or other reasons, stagnant water of river sabarmati the Contractor shall take adequate
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measures such as bailing, pumping, constructing diversion channels, drainage channels, bunds, depression of water level by well-point system, cofferdams and other necessary works to keep the foundation trenches dry when so required and to protect the green concrete/masonry against damage by erosion or sudden rising of water level. The methods to be adopted in this regard and other details thereof shall be left to the choice of the Contractor but subject to approval of the Engineer. Approval of the Engineer shall, however, not relieve the Contractor of the responsibility for the adequacy of dewatering and protection arrangements and for the quality and safety of the works. Where cofferdams are required, these shall be carried to adequate depths and heights, be safely designed and constructed and be made as watertight as is necessary for facilitating construction to be carried out inside them. The interior dimensions of the cofferdams shall be such as to give sufficient clearance for the construction and inspection and to permit installation of pumping equipments etc., inside the enclosed area. If it is determined beforehand that the foundations cannot be laid dry or the situation is found that the percolation is too heavy for keeping the foundation dry, the foundation concrete shall be laid under water by tremie pipe only. In case of flowing water or artesian springs, the flow shall be stopped or reduced as far as possible at the time of placing the concrete. Pumping from the interior of any foundation enclosure shall be done in such a manner as to preclude the possibility of the movement of water through any fresh concrete. No pumping shall be permitted during the placing of concrete or for any period of at least 24 hours thereafter, unless it is done from a suitable sump separated from the concrete work by a watertight wall or other similar means. At the discretion of the Contractor, cement grouting or other approved methods may be used to prevent or reduce seepage and to protect the excavation area. The Contractor shall take all precautions in diverting channels and in discharging the drained water as not to cause damage to the works, crops or any other property. 304.3.4.Preparation of foundation: The bottom of the foundation shall be levelled both longitudinally and transversely or stepped as directed by the Engineer. Before pipe is laid, the surface shall be slightly watered and rammed. In the event of excavation having been made deeper than that shown on the drawings or as otherwise ordered by the Engineer, the extra depth shall be made up with concrete or masonry of the foundation at the cost of the Contractor as per Clause 2104.1. Ordinary filling shall not be used for the purpose to bring the foundation to level.
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304.3.5. Slips and slip-outs: If there are any slips or slip-outs in the excavation, these shall be removed by the Contractor at his own cost. 304.3.6. Public safety: Near towns, villages and all frequented places, trenches and foundation pits shall be securely fenced, provided with proper caution signs and marked with red lights at night to avoid accidents. The Contractor shall take adequate protective measures to see that the excavation operations do not affect or damage adjoining structures. For safety precautions, guidance may be taken from IS : 3764. 304.3.7. Backfilling: Backfilling shall be done with approved material after concrete or masonry is fully set and carried out in such a way as not to cause undue thrust on any part of the structure. All space between foundation masonry or concrete and the sides of excavation shall be refilled to the original surface in layers not exceeding 150 mm compacted thickness. The compaction shall be done with the help of suitable equipment such as mechanical tamper, rammer, plate vibrator etc., after necessary watering, so as to achieve a density not less than the field density before excavation. 304.3.8. Disposal of surplus excavated materials: Clause 301.3.11 shall apply. 304.4.Measurements for Payment Excavation for laying of pipes and manhole shall be measured in cu. m. for each class of material encountered, limited to the dimensions shown on the drawings or as directed by the Engineer, Excavation over increased width, cutting of slopes, shoring, shuttering and planking shall be deemed as convenience for the Contractor in executing the work and shall not be measured and paid for separately. Foundation sealing, dewatering, including pumping is included in the above rates and will not be paid separately. 304.5 Rates 304.5.1. The Contract unit rate for the items of excavation for structures shall be payment in full for carrying out the required operations including full compensation for : (i) (ii) (iii) setting out; construction of necessary cofferdams, cribs, sheeting, shoring and bracing and their subsequent removal; removal of all logs, stumps, grubs and other deleterious matter and obstructions, for placing the foundations including trimming of bottoms of excavations; foundation sealing, dewatering including pumping as no separate provision for it is made in the Contract;
(iv)
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(v) (vi)
backfilling, clearing up the site and disposal of all surplus material within all lifts and leads up to 2000 m or as otherwise specified; and all labour, materials, tools, equipment, safety measures, diversion of traffic and incidentals necessary to complete the work to Specification.
304.5.2. Deleted. The Contract unit rate for transporting material from the excavation for structures shall be full compensation for all labour, equipment, tools, and incidentals necessary on account of the additional haul or transportation involved beyond the initial lead of 2000 m.
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1101. DESCRIPTION 1101.1. This work shall consist of construction of all types of piles for structures in accordance with the details shown on the drawings and conforming to the requirements of these specifications. 1101.2. The construction of pile foundations requires a careful choice of the piling system depending upon subsoil conditions and loading characteristics and type of structure. The permissible limits of total and differential settlements, unsupported length of pile under scour, impact/entanglement of floating bodies and any other special requirements of project are also equally important criteria for selection of the piling system. The method of installing the piles, including details of the equipment shall be submitted by the Contractor and got approved from the Engineer. 1101.3. The work shall be done as per IS : 2911 except as modified herein. 1102. SUBSURFACE INVESTIGATION 1102.1. The complete subsurface investigation of strata in which pile foundations are proposed shall be carried out in advance and by insitu pile tests. For details of geotechnical subsurface explorations reference may be made to Section 2400. At least one borehole for every foundation of the bridge shall be executed. Borings should be carried upto sufficient depths so as to ascertain the nature of strata around the pile shaft and below the pile tip. However, depth of boring shall not be less than: 1) 1.5 times estimated length of pile in soil but not less than 15 m beyond the probable length of pile 2) 15 times diameter of pile in weak/jointed rock but minimum 15 m in such rock 3) 4 times diameter of pile in sound, hard rock but minimum 3 m in such rock 1102.2. The subsurface investigation shall define adequately stratification of sub-strata including the nature and type of strata, its variation and extent and specific properties of the same. The investigation shall be adequate for the purpose of selection of appropriate piling system and for estimating design capacities for different diameters and length of piles. 1102.3. Pressure meter tests may be used in the case of rock, gravel or soil for direct evaluation of strength and compressibility characteristics. Though these tests are of specialised nature they are most appropriate for difficult/uncertain substrata especially for important projects. 1102.4. For piles socketed into rocks, it is necessary to determine the uniaxial compressive strength of the rock and its quality.
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The investigation shall also include location of ground water table and other parameters including results of chemical tests showing sulphate and chloride content and any other deleterious chemical content in soil and/or ground water, likely to affect durability. 1103. TYPE OF PILES The piles may be of reinforced concrete, prestressed concrete, steel or timber. The piles may be of solid or hollow sections or steel cased piles filled with concrete. Concrete piles may be driven cast-in-situ or precast or bored cast-in-situ or precast piles driven into performed bores. The shape of piles may be circular, square, hexagonal, octagonal, H or I Section. 1104. MATERIALS 1104.1. The basic materials shall conform to the specifications for materials given in Section 1000. The specifications for steel reinforcement, structural concrete, prestressed concrete and structural steel to be used in pile foundations shall be as given in the relevant sections. 1104.2. Concrete in Piles Grade of concrete to be used in cast-in-situ piles shall not be less than M 20 and the cement content shall not be less than 400 kg per cubic meter of concrete. Grades of concrete for precast reinforced and prestressed concrete piles shall not be less than M 25 and M 35 respectively. Maximum water cement ratio shall be 0.5 for cast-in-situ piles and 0.45 for precast piles. The minimum slump of concrete for driven cast-in-situ piles shall be 100 mm to 150 mm to 200 mm and that of bored cast-in-situ piles 150 mm to 200 mm. The slump should not exceed 200 mm in any case. Concrete mix should have homogeneous mixture with required workability for the system of piling adopted. Suitable and approved admixtures may be used in concrete mix where necessary. Where piles are exposed to action of harmful chemicals or severe conditions of exposure due to presence of sulphate, chloride etc. it may be preferable to opt for higher grades of concrete restricting water cement ratio to 0.45. Special types of cement, such as sulphate resistant cement may be used where considered appropriate.
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1105. TEST PILES 1105.1. Test piles which are shown on the drawings or specified in the contract or installed by the Contractor on his own to determine the lengths of piles to be furnished shall conform to the requirements for piling as indicated in these specifications, if they are to be incorporated in the completed structure. Test piles that are to become a part of the completed structure shall be installed with the same type of equipment that is proposed to be used for piling in the actual structure. Test piles which are not to be incorporated in the completed structure shall be removed to at least 600 mm below the proposed soffit level of pile cap and the remaining hole shall be backfilled with earth or other suitable material. The piles shall be load tested in accordance with provisions laid down in this section. 1106. PRECAST CONCRETE PILES 1106.1. General Precast concrete piles shall be of the size and shape as shown in the approved drawings. If a square section is employed, the corners shall be chamfered at least 25 mm unless otherwise specified on the drawings. The length of pile shall not normally exceed 25 metres. However, where special equipments for handling and installation are available to the satisfaction of the Engineer, longer length could be permitted. Piles shall be cast with a driving point and for hard driving, shall be shod with a metal shoe approved by the Engineer. 1106.2 Stacking, Storing and Handling D.6.1.25 D.6.1.26 Care shall be taken that all stages of transporting, lifting and handling, piles are not damaged or cracked. During transport and stacking of piles, they shall be supported at the same points as those provided for lifting purposes. If the piles are put down temporarily during handling, they shall be placed on trestles or blocks located at the same points. D.6.1.27 D.6.1.28 Piles shall be stored at least 300 mm above firm level ground which is not liable to unequal subsidence or settlement under the weight of the stack of piles. They shall be placed on timber supports which are level and spaced so as to avoid bending. The supports shall be vertically one above the other. Spaces shall be left round the piles to enable them to be lifted without difficulty. The order of stacking shall be
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such that the older piles can be withdrawn without disturbing newer piles. Separate stacks shall be provided for different lengths of piles. Where piles are stacked in layers, the number of layers shall not exceed three. Whenever curing is needed during storage, arrangements shall be made to enable the piles to be watered. For detailed precautions with regard to curing operations specifications for structural concrete given in Section 1700 shall apply. Before the operation of handling and driving the piles, the minimum periods counted from the time of casting shall be allowed for as indicated in Table 1100-1. Prestressed piles shall not be lifted or handled until fully stressed. TABLE 1100-1 TIME FOR CURING PRECAST PILES Type of cement Minimum periods from time of casting used in casting Strike side End of wet Lift from the pile shutters curing (days) casting bed (hours) (days) Ordinary Portland 24 7 10 Rapid hardening Portland 12 7 7
Drive (days) 28 10
1106.3. Lengthening of Piles Where a pile is to have another length cast on it during driving, the longitudinal reinforcement shall preferably be joined by full penetration butt welding. The concrete at the top of the original pile shall be cut down to expose not less than 200 mm of the bars to avoid spalling of the concrete by heat. The added bars have to be held accurately and rigidly in position during welding. Where facilities on site are insufficient to make proper butt welding practicable, the joint may be made by lapping. The reinforcement at the head of pile will need to be exposed for full anchorage length or 600 mm whichever is greater and the new bars over-lapped for this distance. Unless otherwise specified, the extension of the pile shall be formed to the same crosssectional profile and with concrete of at least the same strength as that specified for the original pile. The stirrup spacing shall in no case be greater than 150 mm. Not more than one extension shall be permitted. In case more than one extension is permitted by the Engineer, only approved mechanical couples shall be used. Driving shall not be resumed until: (i) The strength of the concrete in the extension is at least equal to the specified characteristic strength of concrete in pile, and (ii) The approval of the Engineer has been obtained.
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1106.4. Removal of Surplus Length Any length of pile surplus to that required for incorporation in the structure shall be cut off neatly and removed. During the process of cutting off, it shall be ensured that projecting reinforcement to be anchored into the pile cap and the prestressing strands/wires are not damaged. When stripping prestressed concrete piles, shock release of tendons shall be avoided. Reference may also be made to clause 7.7.1. of IS : 2911(Part I Section 3) in this connection. 1106.5. Risen Piles Level reading should be taken on each pile after driving and again after all the piles are driven. Piles which are found to have risen due to ground heave or as a result of driving adjacent piles, shall be re-driven to the original depth or resistance unless redriving tests on adjacent piles have shown this to be unnecessary. 1106.6. Manufacture The pile should be cast in one continuous operation from end to end of each pile. Manufacture of precast concrete piles shall conform to the guidelines contained in clause Nos. 7.1, 7.2 and 7.3 of IS : 2911 (Part I, Section 3). Pile shall be provided with suitable shoe for protecting the point of the pile during driving in hard ground. Piles shall not be moved from casting bed until the concrete has hardened sufficiently. Piles shall not be driven in less than 28 days after casting or unless their strength at the time of driving is at least that specified for 28 days. 1106.7. Prestressed Concrete Piles D.6.1.29 Additional specifications for precast prestressed concrete piles shall conform to those contained in clause 8 of IS : 2911 (Part I Section 3). 1107. CAST-IN-SITU CONCRETE PILES Cast-in-situ concrete piles may be either installed by making a bore into the ground by removal of material or by driving a metal casing with a shoe at the tip and
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displacing the material laterally. The two types of piles are termed as bored piles and driven piles respectively. Cast-in-situ concrete piles may be cast in metal shells which may remain permanently in place. However, other types of cast-in-situ concrete piles, plain or reinforced, cased or uncased, may be used if in the opinion of the Engineer the soil conditions permit their use and if their design and the methods of placing are satisfactory. The metal casing shall be of sufficient thickness and strength to hold its original form and show no harmful distortion after it and adjacent casings have been driven and the driving core, if any, has been withdrawn. Cast-in-situ concrete driven piles shall be installed using a properly designed detachable shoe at the bottom of the casing. Certain specific requirements of cast-in-situ driven piles shall be as per Clauses 1110 and 1111. Any liner or bore-hole which is improperly located or shows partial collapse that would affect the load carrying capacity of the pile, shall be rejected or repaired as directed by the Engineer at the cost of the Contractor. Wherever practicable, concrete should be placed in a clean dry hole. Where concrete is placed in dry and there is casing present, the top 3 m of the pile shall be compacted using internal vibrators. The concrete should invariably be poured through a tremie with a funnel so that the flow is directed and concrete can be deposited in the hole without segregation. Where the casing is withdrawn from cohesive soils for the formation of cast-insitu pile, the concreting should be done with necessary precautions to minimise the softening of the soil by excess water. Where mud flow conditions exist, the casing of cast-in-situ piles shall not be allowed to be withdrawn. Care shall be taken during concreting to prevent as far as possible the segregation of the ingredients. The displacement or distortion of reinforcement during concreting and also while extracting the tube shall be avoided. If the concrete is placed inside precast concrete tubes or consists of precast sections, these shall be free from cracks or other damage before being installed. The concrete shall be properly graded, shall be self-compacting and shall not get mixed with soil, excess water, or other extraneous matter. Special care shall be taken in silty clays and other soils with the tendency to squeeze into the newly deposited concrete and cause necking. Sufficient head of green concrete shall be maintained to prevent inflow of soil or water into the concrete. The placing of concrete shall be a continuous process from the toe level to the top of the pile. To prevent segregation, a tube or tremie pipe as appropriate shall be used to place concrete in all piles.
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To ensure compaction by hydraulic static heads, rate of placing concrete in the pile shaft shall not be less than 6 m (length of pile) per hour. Bored cast-in-situ piles in soils which are stable, may often be installed with only a small casing length at the top. A minimum of 2.0 m length of top of bore shall invariably be provided with casing to ensure against loose soil falling into the bore. In cases in which the side soil can fall into the hole, it is necessary to stabilise the side of the bore hole with drilling mud, or a suitable steel casing. The casing may be left in position permanently specially in cases where the aggressive action of the ground water is to be avoided, or in the cases of piles built in water or in cases where significant length of piles could be exposed due to scour. For bored cast-in-situ piles, casting/liner shall be driven open ended with a pile driving hammer capable of achieving penetration of the liner to the length shown on the drawing or as approved by the Engineer. Materials inside the casing shall removed progressively by air lift, grab or percussion equipment or other approved means. Where bored cast-in-situ piles are used in soils liable to flow, the bottom of the casting shall be kept enough in advance of the boring tool to prevent the entry of soil into the casing, thus preventing the formation of cavities and settlements in the adjoining ground. The water level in the casing should generally be maintained at the natural ground water level for the same reasons. The joint of the casing shall be made as tight as possible to minimise inflow of water or leakage of slurry during concreting. Boring shall be carried out using rotary or percussion type equipment. Unless otherwise approved by the Engineer, the diameter of the bore-holes shall be not more than the inside diameter of the liner. Prior to the lowering of the reinforcement cage into the pile shaft, the shaft shall be cleaned of all loose materials. Cover to reinforcing steel shall be maintained by suitable spacers. The diameter of the finished pile shall not be less than that specified and a continuous record shall be kept by the Engineer as to the volume of concrete placed in relation to the length cast. Before concreting under water, the bottom of the hole shall be cleaned of drilling mud and all soft or loose material very carefully. In case a hole is bored with use of drilling mud, concreting should not be taken up when the specific gravity of bottom slurry is more than 1.2. The drilling mud should be maintained at 1.5 m above the ground water level. Concreting under water for cast-in-situ concrete piles may be done either with the use of tremie method or by the use of an approved method specially designed to permit under water placement of concrete.
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General requirements and precautions for concrete under water are as follows: (a) The concreting of a pile must be completed in one continuous operation. Also, for bored holes, the finishing of the bore, cleaning of the bore, lowering of reinforcement cage and concreting of pile for full height must be accomplished in one continuous operation without any stoppage. The concrete should be coherent, rich in cement with high slump and restricted water cement ratio. The tremie pipe will have to be large enough with due regard to the size of aggregate. For 20 mm aggregate the tremie pipe should be of diameter not less than 150 mm and for large aggregate, larger diameter tremie pipes may be necessary. The first charge of concrete should be placed with a sliding plug pushed down the tube ahead of it to prevent mixing of water and concrete. The tremie pipe should always penetrate well into the concrete with an adequate margin of safety against accidental withdrawal if the pipe is surged to discharge the concrete. The pipe should be concreted wholly by tremie and the method of deposition should not be changed part way up the pile to prevent the laitance from being entrapped within the pipe. All tremie tubes should be scrupulously cleared after use.
(b) (c)
(d) (e)
(f)
(g)
The minimum embedment of cast-in-situ concrete piles into pile cap shall be 150 mm. Any defective concrete at the head of the completed pile shall be cut away and made good with new concrete. The clear cover between the bottom reinforcement in pile cap from the top of the pile shall be not less than 25 mm. The reinforcement in the pile shall be exposed for full anchorage length to permit it to be adequately bonded into the pile cap. Exposing such length shall be done carefully to avoid damaging the rest of the pile. In cases where the pipe cap is to be laid on ground, a leveling course of M 15 nominal mix concrete 100 mm thick shall be provided. Defective piles shall be removed or left in place as judged convenient without affecting the performance of adjacent piles or pile cap. Additional piles shall be provided to replace the defective piles.
Signature of Bidder
1108. STEEL PILES Steel piles shall be H or I sections as shown on the drawings and shall be of structural steel conforming to the specifications given in Section 1000. Steel piles shall be protected by suitable anti-corrosive painting as specified on the drawing. Piles shall be stored above the ground using protective packing to minimise damage to surface coating. Each pile shall be supplied preferably in one piece without splices. At the option of the Contractor, steel piling consisting of structural steel plates welded together may be substituted for the rolled sections specified, provided that the depth, width and average thicknesses are at least equal to those of the rolled sections, the steel plates conform to specification given in Section 1000, the flanges are welded to the web with continuous fillet welds on either side of the web, and the welding conforms to Clause 1904.8 of these specifications. The length of the steel pile may be built up in sections either before or during driving operations. The sections shall be of identical cross-section. Pile splices shall be made with full penetration butt welds over the whole cross-section. Pile splices shall develop at least the yield strength of pile. The connections shall be made by butt-welding the entire cross-section in accordance with the provisions in Clause 1904.8 of these specifications. Care shall be taken to properly align the sections connected so that the axis of the pile will be straight. The number of welded connections in the length of pile shall be as few as possible. 1109. Timber Piles The Engineer shall stamp each pile on the butt with a stamp which shall make an impression that is readily legible. Treated timber piles will be inspected by the Engineer after treatment. Untreated timber may be used as test piles. Untreated timber piles and treated timber piles shall be of approved quality. Treated timber piles shall be driven within 6 months after treatment. Timber piles shall be furnished with tip protection and shall be protected by the use of steel straps as hereinafter specified. Tip protection shall be suitable for use on timber piling of the size to be driven. Details of tip protection shall be furnished to the Engineer for review and approval before driving piles. Not less than 2 separate steel straps shall be placed within 600 mm of the butt of each pile after the pile is square cut. Not less than 2 separate steel straps shall be placed within 300 mm of the tip of each pile.
Signature of Bidder
Additional intermediate steel straps shall be placed at not more than 3 metres centre measured along the length of the pile. Timber piles which are to be capped shall be separately cut off so that true bearing is obtained on every pile. Piles inaccurately cut off shall be replaced. Splicing of timber piles shall not be permitted except by written permission of the Engineer. 1110.Driving Equipment Piles or their casings may be driven with any type of drop hammer, diesel hammer or single-acting steam or compressed air hammer, provided they penetrate to the prescribed depth or attain the designed resistance without being damaged. The weight or power of the hammer should be sufficient to ensure a penetration of at least 5 mm per blow, unless rock has been reached. It is always preferable to employ the heaviest hammer practicable and to limit the stroke, so as not to damage the pile. The minimum weight of the hammer shall be 2.5t. In the case of precast concrete piles the mass of the hammer shall be not less than 30 times the mass of 300 mm length of pile. Stream or air hammers shall be furnished along with boiler or air compressor of capacity at least equal to that specified by the manufacturer of the hammers. The boiler or air compressor shall be equipped with an accurate pressure gauge at all times. The valve mechanism and other parts of steam, air or diesel hammers shall be maintained in first class condition so that the length of stroke and number of blows per minute for which the hammer is designed, will be obtained. Inefficient steam, air or diesel hammers shall be removed from the work. 1111. DRIVING 1111.1. General Procedure Details of the equipment and the method proposed for driving the piles shall be submitted with the tender for scrutiny and approval of the Engineer. Piles shall be installed from firm ground or from temporary supports or from fixed platform. The arrangement shall provide sufficient rigidity to ensure accuracy of pile driving under all conditions of tide, stream flow or hammer drop. During driving the top of pile shall be protected by a suitable helmet of substantial steel construction. The helmet shall provide uniform bearing across the top of the pile and shall hold the pile centrally under the hammer. No pile shall be driven unless inspected and approved by the Engineer. Piles shall be driven from a fixed frame of sufficient rigidity to ensure accuracy of driving within specified tolerances. Forces producing undue bending or torsional stresses in piles shall not be applied during driving. The force of the hammer shall be directed centrally and axially during driving.
Signature of Bidder
The stroke of a single acting or drop hammer shall be limited to 1.2 m unless otherwise permitted by the Engineer. A shorter stroke may be necessary when is danger of damaging the pile. Piles shall not be bent or sprung into position but shall be effectively guided and held on-line during the initial stages of driving. Attempts to correct any tendency for the pile to run off-line by the application of significant horizontal restraint will not be permitted. Shortly after the commencement of driving and at regular intervals throughout the driving operation, checks shall be made to ensure that the pile frame does not exert any undue lateral force on the pile due to restraint within the helmet. If the indications are that a pile will finish outside the specified tolerances, driving operations on that pile will cease. The pile shall be withdrawn, the hole filled and the pile re-driven at no extra cost. To avoid the possibility of premature set-up pile driving shall be continuous in the later stages, without any deliberate stops. (Delays of an hour or less may lead to significant set-up in piles i.e. resistance to further driving increases after driving is stopped). If any pile is damaged in any way during driving, it shall be repaired or replaced as directed by the Engineer, at no extra cost. If during driving, the head of a pile is damaged to the extent that further driving is not possible, the head shall be cut off and driving continued. The cost of cutting off shall be borne by the Contractor and where, as a result of such cutting off the head, the pile is too short, the Contractor, shall, at his own cost, supply and splice on sufficient length of pile to restore the pile to its correct length. Piles should be driven to the minimum acceptable penetration shown on the drawings. This may require preboring and/or jetting as indicated in these specifications with the full approval of the Engineer. Piles shall be driven to nominal refusal or the required ultimate dynamic capacity nominated on the drawings or until the top of the pile is at the level required and specified on the drawing whichever gives the lowest toe elevation. The Engineers decision in these matters shall be final. Nominal refusal shall be taken as equivalent to 25 mm total penetration for the final 20 blows using a hammer of driving energy as specified and shall be used as the criterion for acceptance for piles founded on rock. Severe driving which results in an average set per blow less than 0.5 mm will not be permitted. Where hard drilling is encountered because of dense strata or obstructions located above the predetermined pile tip level, nominal refusal shall not be considered to have been achieved unless the Engineer is satisfied that the total number of blows, as the average driving resistance specified for nominal refusal, indicates that further driving will not advance the pile through dense strata or obstructions.
Signature of Bidder
The pile shall be driven as accurately as possible to the vertical or to specified batter. Straining the pile into position can damage it and the driving equipment should be adjusted as much as possible to follow the position of the pile. Any deviation from the proper alignment shall be noted and promptly reported to the Engineer. If the deviation is to such an extent that the resulting eccentricity cannot be taken care of by strengthening the pile cap or pile ties, such a pile shall, at the discretion of the Engineer, be replaced or supplemented by an additional pile. Unless otherwise specified, the permissible positional deviation for piles shall be limited to those indicated in Clause 1116. Care shall be taken not to damage the pile by over-driving. Any sudden change in the rate of penetration which cannot be ascribed to the nature of the ground shall be noted and its cause ascertained, if possible, before driving is continued. When employing a tube which is subsequently withdrawn for the formation of cast-in-situ pile, consideration shall be given to the possibility of doing harm to a pile recently formed by driving the tube nearby before the concrete has sufficiently set. The danger of doing harm is greater in compact soils than loose soils. No pile shall be bored or driven within 3 m of a newly cast pile until at least 24 hours after completion of its installation. Driving piles in loose sand tends to compact the sand which in turn increases the skin friction. Therefore, driving a number of friction piles in a group shall proceed outward from the centre as otherwise it will be difficult to drive the inner piles to the same depth as the others. In case of stiff clay also, the driving for a group of piles shall proceed outward from the centre. However, in case of very soft soil, the driving may proceed from outside to inside, so that the soil is restrained from flowing out during driving operations. If there is a major variation between the depth at which adjacent foundation piles in a group meet refusal, a boring shall be made nearby to ascertain the cause of this difference. If the boring shows that the soil contains pockets of highly compressive material below the level of the shorter pile, it will be necessary to enforce penetration of all the piles to a level below the bottom of the zone which shows such pockets. 1111.2. Preboring and Jetting Driving of the piles may be assisted by preboring holes or by the use of jets or both subject to the approval of the Engineer. These may be used essentially to achieve the minimum penetration shown on the drawings where such penetration is not reached under normal conditions of driving indicated in Clause 1111.1. The diameter of the hole shall not be greater than the diagonal dimension of the pile less 100 mm.
Signature of Bidder
The maximum depth of the preboring shall be such that the specified set (or less) is obtained when the toe of the pile is at founding level. Preboring shall be as approved by the Engineer and shall not extent below one metre above the founding level and the pile shall be driven to at least one metre below the prebored hole. To ensure that the pile is properly supported laterally in the hole, any space remaining around the pile at the ground level after driving is finished shall be backfilled with approved granular material. When water jetting is used, at least two jets shall be attached to the pile symmetrically when this type of technique is used. The volume and pressure of water at the outlet nozzles shall be sufficient to freely erode material adjacent to the toe of the pile. The maximum depth of jetting shall be such that the specified set (or less) is obtained when the toe of the pile is at founding level. Jetting shall cease as directed by the Engineer and shall not proceed below one metre above the founding level and the pile shall be driven at least one metre below the pre-bored hole. To avoid very hard driving and vibration in materials such as sand, jetting of piles by means of water may be carried out only by express permission of the Engineer and in such a manner as not to impair the bearing capacity of the piles already in place, the stability of the soil or the safety of any adjoining buildings. Details of the arrangement for jetting shall be got approved from the Engineer in advance. If, for jetting, large quantities of water are used, it may be necessary to make provision for collection of water when it comes to the ground surface, so that the stability of the piling plant is not endangered by the softening of the ground. Jetting shall be stopped before completing the driving which shall always be finished by ordinary methods. Jetting shall be stopped if there is any tendency for the pile tips to be drawn towards the pile already driven owing to the disturbance to the ground. 1112. RAKER (INCLINED) PILES The maximum rake to be permitted in piles shall not exceed the following: i) ii) iii) 1 in 8 for larger diameter cast-in-situ piles viz 0.75 m diameter and above 1 in 5 for smaller diameter cast-in-situ piles 1 in 4 for precast driven piles 1113. PILE TESTS 1113.1. General The bearing capacity of a single pile may be determined from test loading a pile. The load test on a concrete pile may not be carried out earlier than 28 days from the time of casting of the pile.
Signature of Bidder
There shall be two categories of test on piles, namely, initial tests and routine tests. Initial tests should be carried out on test piles which are not be incorporated in the work. Routine tests shall be carried out as a check on working piles. The number of initial and routine tests on piles shall be as determined by the Engineer depending upon the number of foundations, span length, type of superstructure and uncertainties of founding strata. In any case, the initial load tests shall not be less than 2 in number, while the routine load tests shall not be less than 2 percent of the total number of piles in the structure nor less than 2 in number. The above stipulations hold good for both vertical as well as lateral load tests on pile foundations. However, both initial and routine tests may be suitably increased for important structures or cases with large variation in the sub-surface strata. The methodology of carrying out load tests and of arriving at safe load on piles shall conform to IS : 2911 (Part IV). In case of any doubt of workmanship or load carrying capacity of working piles not subjected to routine tests, or when ordered by the Engineer, or when provided in the contract, load tests on working piles may be supplemented by non-destructive testing. Such tests may include Integrity Testing of concrete in the installed pile and utilisation of Pile Driving Analyser which gives an indication of pile capacity in end bearing and side friction. 1114. PILE CAP Pile Caps shall be of reinforced concrete. A minimum offset of 150 mm shall be provided beyond the outer faces of the outer most piles in the group. If the pile cap is in contact with earth at the bottom, a levelling course of minimum 100 mm thickness of M 15 nominal mix concrete shall be provided. The attachment of the pile head to the cap shall be adequate for the transmission of loads and forces. A portion of pile top may be stripped of concrete and the reinforcement anchored into the cap. Manual chipping may be permitted after three days of pile casting, while pneumatic tools for chipping shall not be used before seven days after pile casting. The top of pile after stripping shall project at least 150 mm into the pile cap. A layer of surface reinforcement may be provided with a cover of 25 mm to retain the integrity of concrete below the main cap reinforcement which is to be laid 25 mm above the pile top. Concreting of the pile cap shall be carried out in dry conditions. The bottom of the pile cap shall be laid preferably as low as possible taking account of the water level prevalent at the time of casting.
Signature of Bidder
The top of concrete in a pile shall be brought above cut-off level to permit removal of all laitance and weak concrete before pile cap is laid. This will ensure good concrete at the cut-off level.
1115.
IMPORTANT CONSIDERATIONS, INSPECTION/PRECAUTIONS FOR DIFFERENT TYPES OF PILES
1115.1. Driven Cast-in-Situ Piles 1115.1.1.Specialist literature and the guidelines from the pile construction industry shall be consulted regarding the method of installation, equipment and accessories for pile driving and recording of data. 1115.1.2.During installation of piles the final setof penetration of pile per blow of hammer shall be checked taking an average of last 10 blows. 1115.1.3.The pile shoes which may be of either cast iron conical type or mild steel flat type shall have double reams for proper seating of the removable casing tube inside the space between the reams. 1115.1.4.Before commencement of pouring of concrete, it shall be ensured that there is no ingress of water in the casing tube from the bottom. Further adequate control during withdrawal of the casing tube is essential so as to maintain sufficient head of concrete inside the casing tube at all stages of withdrawal. 1115.1.5. Concrete in piles shall be cast upto a minimum height of 600 mm above the designed top level of pile, which shall be stripped off at the time of construction of pile cap. 1115.2. Bored Cast-in-situ Piles 1115.2.1. While concreting uncased piles, voids in concrete shall be avoided and sufficient head of concrete is to be maintained to prevent inflow of soil or water into the concrete. It is also necessary to take precautions during concreting to minimise the softening of the soil by excess water. Uncased cast-in-situ piles shall not be allowed where mudflow conditions exist. 1115.2.2. The drilling mud such as bentonite suspension shall be maintained at a level sufficiently above the surrounding ground water level to ensure the stability of the strata which is being penetrated throughout the boring process until the pile has been concreted.
Signature of Bidder
111.5.2.3. Where bentonite suspension is used to maintain the stability of the bore-hole, it is essential that the properties of the material be carefully controlled at stages of mixing, supply to the bore-hole and immediately before concrete is placed. It is usual to limit: i) ii) iii) iv) v) The density of bentonite suspension to 1.05 g/cc The marsh cone viscosity between 30 and 40 The pH value between 9.5 and 12 The silt content less than 1 per cent The liquid limit of bentonite not less than 400 per cent
These aspects shall act as controlling factors for preventing contamination of bentonite slurry for clay and silt. 1115.2.4. The bores shall be washed by bentonite flushing to ensure clean bottom at two stages viz. after completion of boring and prior to concreting after placing of reinforcement cage. Flushing of bentonite shall be done continuously with fresh bentonite slurry till the consistency of inflowing and out-flowing slurry is similar. 1115.2.5.Tremie of 150 mm to 200 mm diameter shall be used for concreting. The tremie should have uniform and smooth cross-section inside, and shall be withdrawn slowly ensuring adequate height of concrete outside the tremie pipe at all stages of withdrawal. Other recommendations for tremie concreting are: (i) (ii) (iii) The sides of the bore-hole have to be stable throughout. The tremie shall be water-tight throughout its length and have a hopper attached at its head by a water-tight connection. The tremie pipe shall be large enough in relation to the size of aggregates. For 20 mm aggregate the tremie pipe shall be of diameter not less than 150 mm and for larger size aggregate tremie pipe of larger diameter is required.
Signature of Bidder
(iv) (v)
The tremie pipe shall be lowered to the bottom of the bore-hole, allowing water or drilling mud to rise inside it before pouring concrete. The tremie pipe shall always be kept full of concrete and shall penetrate well into the concrete in the bore-hole with adequate margin of safety against accidental withdrawal if the pipe is surged to discharge the concrete.
1115.2.6. For very long or large diameter piles, use of retarding plasticiser in concrete is desirable. 1115.2.7. For large diameter piles, it may be essential to conduct non-destructive pile integrity tests to evaluate integrity of the pile. 1115.2.8.Where possible, it may be desirable to grout the base of pile with cement slurry under suitable pressure after concrete in the pile attains the desired strength. For this purpose, conduit pipes with easily removable plugs at the bottom end should be placed in the bore alongwith reinforcement cage before concreting. 1116. TOLERANCES 1116.1. Permissible Tolerances for Pile (i) Precast Concrete Piles: (a) (b) (c) (d) (ii) Variation in cross-sectional dimensions Variation in length Surface irregularities measured with 3 m straight edge Bow for length in mm : 5 mm : 25 mm : 5mm : Pile Length in mm 1000
Driven Piles (a) (b) (c) (d) Variation in cross-sectional dimensions Variation from vertical or specified rake Variation in the final position of the head in plan Variation of level of top of piles : +50 mm, -10 mm : 1 in 50 : 75mm : 25 mm
(iii)
Bored Piles (a) (b) (c) Variation in cross-sectional dimensions Variation from vertical or specified rake Variation in the final position of the head in plan : + 50 mm, -10 mm : 1 in 50 : 50 mm
Signature of Bidder
(d)
Variation of level of top of piles
: 25 mm
1116.2. Permissible Tolerances for Pile Caps (a) (b) (c) (d) 1117. Variation in dimensions Misplacement from specified position in plan Surface irregularities measured with 3 m straight edge Variation of levels at the top : +50 mm, -10 mm : 15mm : 5mm : 25 mm
TESTS AND STANDARDS OF ACCEPTANCE
The materials shall be tested in accordance with these Specifications and shall meet the prescribed criteria. The work shall conform to these Specifications and shall meet the prescribed standards of acceptance. 1118. MEASUREMENTS FOR PAYMENT
For supply of precast concrete, timber or steel piles of specified cross-section, the measurement shall be in metres of the length of piles ordered in writing by the Engineer measured from the head to the butt of the shoe or the tapered point. Reinforcement in precast concrete piles shall not be measured for payment. For cast-in-situ driven and bored concrete piles of specified cross-section, the measurement shall be the length in metres of the accepted pile that remains in the finished structure complete in place. Reinforcement in cast-in-situ driven and bored concrete piles shall be measured for payment as per Section 1600. Routine and Initial Pile Load Tests shall not be measured for payment. For installation of the pile, i.e. by driving in the case of precast concrete, timber, steel and cast-in-situ driven piles, and by boring in the case of cast-in-situ bored piles the measurement shall be the length in metres that remains in the finished structure complete in place, limited to that shown on drawings or ordered by the Engineer. No distinction shall be made for penetration through hard strata or rock and socketing into rock. For steel liners/casing shown on the drawings to be permanently left in place, the measurement shall be by weight in tonnes that remains in the finished structure complete in place, limited to that shown on drawings or ordered by the Engineer. For the pile cap, the quality of concrete shall be measured in cubic metres as per Section 1700. While reinforcement in pile cap shall be measured in tonnes as per Section 1600.
Signature of Bidder
1119. RATE The contract unit for supplying precast concrete, timber or steel piles shall include cost of all labour, materials, tools and equipment, and other work involved in making or fabricating the pile complete as shown on the drawing, and where required its loading, transport, delivery to site unloading and stacking it at the place indicated by the Engineer. The cost of reinforcement as per Section 1600 in precast concrete piles shall be deemed to be included in the quoted rate for supply of piles. The contract unit rate for cast-in-situ driven and bored piles shall include the cost of concrete and all other items as per Section 1700. The contract unit shall also include costs of all labour, materials, equipments and all other incidentals involved in conducting routine and initial pile load tests including installation of piles for initial load tests. The contract unit rate for reinforcement in cast-in-situ driven and bored piles shall be as per Section 1600. The contract unit for installation of piles shall include full compensation for furnishing all labour, materials, tools and equipment, and incidentals for doing all the works involved in driving timber, precast concrete and steel piles, driving or making bores for cast-in-situ driven and bored concrete piles, cutting off pile heads, all complete in place to the specified penetration of piles. Providing temporary liner/casing and its withdrawal and placing reinforcement in position shall also be deemed to be included in the rate for installation of piles and no additional payment shall be made for the same. The contract unit rate for permanent steel liners shall include cost of all labour, fabrication and placing the steel liner to the required depth as shown on the drawings and as ordered by the Engineer.
The contract unit rate for concrete in pile cap shall cover all costs of labour, materials, tools, plant and equipment, formwork and staging including placing in position, sampling and testing and supervision, all as per Section 1700. Reinforcement in the pile cap shall be paid for separately as per Section 1600.
Signature of Bidder
1601.
DESCRIPTION
This work shall consist of furnishing and placing coated or uncoated mild steel or high strength deformed reinforcement bars (untensioned) of the shape and dimensions shown on the drawings and conforming to these Specifications or as approved by the Engineer. 1602. GENERAL Steel for reinforcement shall meet with the requirements of Section 1000 . Reinforcements may be either mild steel/medium tensile steel or high strength deformed bars. They may be uncoated or coated with epoxy or with approved protective coatings. 1603. PROTECTION OF REINFORCEMENT
Uncoated reinforcing steel shall be protected from rusting or chloride contamination. Reinforcements shall be free from rust, mortar, loose mill scale, grease, oil or paints. This may be ensured either by using reinforcement fresh from the factory or thoroughly cleaning all reinforcement to remove rust using any suitable method such as sand blasting, mechanical wire brushing, etc., as directed by the Engineer. Reinforcements shall be stored on block, racks or platforms and above the ground in a clean and dry condition and shall be suitably marked to facilitate inspection and identification. Portions of uncoated reinforcing steel and dowels projecting from concrete, shall be protected within one week after initial placing of concrete with a brush coat of neat cement mixed with water to a consistency of thick paint. This coating shall be removed by lightly tapping with a hammer or other tool not more than one week before placing of the adjacent pour of concrete. Coated reinforcing steel shall be protected against damage to the coating. If the coating on the bars is damaged during transportation or handling and cannot be repaired, the same shall be rejected. 1604. BENDING OF REINFORCEMENT
Bar bending schedule shall be furnished by the Contractor and got approved by the Engineer before start of work. Reinforcing steel shall conform to the dimensions and shapes given in the approved Bar Bending Schedules. Bars shall be bent cold to the specified shape and dimensions or as directed by the Engineer using a proper bar bender, operated by hand or power to obtain the correct radii of bends and shape.
Signature of Bidder
Bars shall not be bent or straightened in a manner that will damage the parent material or the coating. Bars bent during transport or handling shall be straightened before being used on work and shall not be heated to facilitate straightening. 1605. a) PLACING OF REINFORCEMENT
The reinforcement cage should generally be fabricated in the yard at ground level and then shifted and placed in position. The reinforcement shall be placed strictly in accordance with the drawings and shall be assembled in position only when the structure is otherwise ready for placing of concrete. Prolonged time gap between assembling of reinforcements and casting of concrete, which may result in rust formation on the surface, shall not be permitted. Reinforcement bars shall be placed accurately in position as shown on the drawings. The bars, crossing one another shall be tied together at every intersection with binding wire (annealed), conforming to IS : 280 to make the skeleton of the reinforcement rigid such that the reinforcement does not get displaced during placing of concrete, or any other operation. The diameter of binding wire shall not be less than 1mm. Bars shall be kept in position usually by the following methods:
b)
c)
(i) In case of beam and slab construction, industrially produced polymer cover blocks of thickness equal to the specified cover shall be placed between the bars and formwork subject to satisfactory evidence that the polymer composition is not harmful to concrete and reinforcement. Cover blocks made of concrete may be permitted by the Engineer, provided they have the same strength and specification as those of the member. (ii) In case of dowels for columns and walls, the vertical reinforcement shall be kept in position by means of timber templates with slots cut in them accurately, or with cover blocks tied to the reinforcement. Timber templates shall be removed after the concreting has progressed upto a level just below their location. (iii) Layers of reinforcements shall be separated by spacer bars at approximately one metre intervals. The minimum diameter of spacer bars shall be 12 mm or equal to maximum size of main reinforcement or maximum size of coarse aggregate, whichever is greater. Horizontal reinforcement shall not be allowed to sag between supports.
Signature of Bidder
(iv)
Necessary stays, blocks, metal chairs, spacers, metal hangers, supporting wires etc, or other subsidiary reinforcement shall be provided to fix the reinforcements firmly in its correct position. Use of pebbles, broken stone, metal pipe, brick, mortar or wooden blocks etc., as devices for positioning reinforcement shall not be permitted.
(v)
d)
Bars coated with epoxy or any other approved protective coating shall be placed on supports that do not damage the coating. Supports shall be installed in a manner such that planes of weakness are not created in hardened concrete. The coated reinforcing steel shall be held in place by use of plastic or plastic coated binding wires especially manufactured for the purpose. Reference shall be made to Section 1000 for other requirements. Placing and fixing of reinforcement shall be inspected and approved by the Engineer before concrete is deposited. 1606. BAR SPLICES
e)
1606.1. Lapping
All reinforcement shall be furnished in full lengths as indicated on the drawing. No splicing of bars, except where shown on the drawing, will be permitted without approval of the Engineer. The lengths of the splice shall be as indicated on drawing or as approved by the Engineer. Where practicable, overlapping bars shall not touch each other, and shall be kept apart by 25 mm or 1 times the maximum size of coarse aggregate, whichever is greater. If this is not feasible, overlapping bars shall be bound with annealed steel binding wire, not less than 1 mm diameter and twisted tight in such a manner as to maintain minimum clear cover to the reinforcement from the concrete surface. Lapped splices shall be staggered or located at points, along the span where stresses are low. 1606.2. Welding 1606.2.1.Splicing by welding of reinforcement will be permitted only if detailed on the drawing or approved by the Engineer. Weld shall develop an ultimate strength equal to or great than that of the bars connected.
Signature of Bidder
1606.2.2. While welding may be permitted for mild steel reinforcing bars conforming to IS : 432, welding of deformed bars conforming to IS : 1786 shall in general be prohibited. Welding may be permitted in case of bars other than S 240 grade including special welding grade of S 415 grade bars conforming to IS : 1786, for which necessary chemical analysis has been secured ad the carbon equivalent (CE) calculated from the chemical composition using the formula: CE = C + Mn + Cr+Mg+V + Ni + Cu 6 5 15 is 0.4 or less. 1606.2.3. The method of welding shall conform to IS : 2751 and IS : 9417 and to any supplemental specifications to the satisfaction of the Engineer. Welding may be carried out by metal arc welding process. Oxyacetylene welding shall not be permissible. Any other process may be used subject to the Engineer and necessary additional requirements to ensure satisfactory joint performance. Precautions on over heating, choice of electrode, selection of correct current in arc welding etc., should be strictly observed. All bars shall be butt welded except for smaller diameter bars (diameter of less than 20 mm) which may be lap welded. Single-V or Double-V butt joints may generally be used. For vertical bars single bevel or double bevel joints may be used. Welded joints shall be located well away from bends and not less than twice the bar diameter away from a bend. Generally, shop welding in controlled conditions is to be preferred, where feasible. Site welding where necessary shall, however, be permitted when the facilities, equipment, process, consumables, operators, welding procedure are adequate to produce and maintain uniform quality at par with that attainable in shop welding to the satisfaction of the Engineer. Joint welding procedures which are to be employed shall invariably be established by a procedure specification. All welders and welding operators to be employed shall have to be qualified by tests prescribed in IS : 2751. Inspection of welds shall conform to IS : 822 and destructive or non-destructive testing may be undertaken when deemed necessary. Joints with weld defects detected by visual inspection or dimensional check inspection shall not be accepted. Suitable means shall be provided for holding the bars securely in position during welding. It must be ensured that no voids are left in welding. When welding is done in 2 or 3 stages, previous surface shall be cleaned properly. Bars shall be cleaned of all loose scale, rust, grease, paint and other foreign matter before carrying out welding. Only
Signature of Bidder
competent and experienced welders shall be employed on the work with the approval of the Engineer. No welding shall be done on coated bars. M.S. electrodes used for welding shall conform to IS : 814. 1606.2.4. Welded joints shall preferably be located at points where steel will not be subject to more than 75 per cent of the maximum permissible stresses and welds so staggered that at any on section, not more than 20 per cent of the bars are welded. 1606.2.5. Welded pieces of reinforcement shall be tested. Specimens shall be taken from the site and the number and frequency of tests shall be as directed by the Engineer. 1606.3. Mechanical Coupling of Bars Bars may be jointed with approved patented mechanical devices as indicated on the drawing or as approved by the Engineer e.g. by special grade steel sleeves swagged on to bars in end to end contact or by screwed couplers. In case such devices are permitted by the Engineer, they shall develop at least 125 per cent of the characteristic strength of the reinforcement bar. 1607. TESTING AND ACCEPTANCE
The material shall be tested in accordance with relevant IS specifications and necessary test certificates shall be furnished. Additional tests, if required, will be got carried out by the Contractor at his own cost. The fabrication, furnishing and placing of reinforcement shall be in accordance with these specifications and shall be checked and accepted by the Engineer. 1608. MEASUREMENTS FOR PAYMENT
Reinforcement shall be measured in length including hooks, if any, separately for different diameters as actually used in work, excluding overlaps. From the length so measured, the weight of reinforcement shall be calculated in tonnes on the basis of IS : 1732. Wastage, overlaps, couplings, welded joints, spacer bars, chairs, stays, hangers and annealed steel wire or other methods for binding and placing shall not be measured and cost of these items shall be deemed to be included in the rates for reinforcement.
Signature of Bidder
1609.
RATE
The contract unit rate for coated/uncoated reinforcement shall cover the cost of material, fabricating, transporting, storing, bending, placing, binding and fixing in position as shown on the drawings as per these specifications and as directed by the Engineer, including all labour, equipment, supplies, incidentals, sampling, testing and supervision.
The unit rate for coated reinforcement shall be deemed to also include cost of all material, labour, tools and plant, royalty, transportation and expertise required to carry out the work. The rate shall also cover sampling, testing and supervision required for the work.
Signature of Bidder
1701. DESCRIPTION The work shall consist of furnishing and placing structural concrete and incidental construction in accordance with these specifications and in conformity with the lines, grades and dimensions, as shown on the drawings or as directed by the Engineer. 1702. MATERIALS All materials shall conform to Section 1000 of these Specifications. 1703. GRADES OF CONCRETE 1703.1. The grades of concrete shall be designated by the characteristic strength as given in Table 1700-1, where the characteristic strength is defined as the strength of concrete below which not more than 5 per cent of the test results are expected to fall. TABLE 1700-1. Grade Designation Specified characteristic Compressive strength of 150 mm cubes at 28 days, in MPa 15 20 25 30 35 40 45 50 55
D.6.1.30
M 35
M 15 M 20 M 25 M 30 M 40 M 45 M 50 M 55
1703.2. The lowest grades of concrete in bridges and corresponding minimum cement contents and water-cement ratios shall be maintained as indicated in Tables 17002 and 1700-3.
Signature of Bidder
1700-2.
FOR BRIDGES WITH PRESTRESSED CONCRETE OR THOSE WITH INDIVIDUAL SPAN LENGTHS MORE THAN 30 M OR THOSE THAT ARE BUILT WITH INNOVATIVE DESIGN/CONSTRUCTION
(A) MINIMUM CEMENT CONTENT AND MAXIMUM WATER CEMENT RATIO Structural Member
Min. cement content for all exposure conditions
Max. water cement ratio Exposure conditions Normal 0.45 0.45 0.40 Severe 0.45 0.40 0.40
a) PCC members b) RCC members c) PSC members
(kg/cu.m.) 360 400 400
(B) MINIMUM STRENGTH OF CONCRETE Member a) PCC members b) RCC members c) PSC members TABLE 1700-3. Conditions of Exposure Moderate M 25 M 35 M 35 Severe M 30 M 40 M 40
FOR BRIDGES OTHER THAN THOSE MENTIONED IN TABLE 1700-2 AND FOR CULVERTS AND OTHER INCIDENTAL CONSTRUCTION
(A) MINIMUM CEMENT CONTENT AND MAXIMUM WATER CEMENT RATIO Structural Member Min. cement content (kg/cu.m.) Exposure conditions a) PCC members b) RCC members Normal 250 310 Severe 310 400 Max. water cement ratio Exposure conditions Normal 0.50 0.45 Severe 0.45 0.40
Signature of Bidder
(B) MINIMUM STRENGTH OF CONCRETE Member a) PCC members b) RCC members Conditions of Exposure Moderate M 15 M 20 Severe M 20 M 25
Notes Applicable to Tables 1700-2 and 1700-3 (i) The minimum cement content is based on 20 mm aggregate (nominal max. size). For 40 mm and larger size aggregates, it may be reduced suitably but the reduction shall not be more than 10 per cent. For underwater concreting, the cement content shall be increased by 10 per cent. Severe conditions of exposure shall mean alternate wetting and drying due to sea spray, alternate wetting and drying combined with freezing and buried in soil having corrosive effect. Moderate conditions of exposure shall mean other that those mentioned in (iii) above.
(ii) (iii)
(iv)
The cement content shall be low as possible but not less than the quantities specified above. In no case shall it exceed 540 kg/cu.m. of concrete. 1703.3. Concrete used in any component or structure shall be specified by designation along with prescribed method of design of mix i.e. Design Mix or Nominal Mix. For all items of concrete, only Design Mix shall be used, except where Nominal Mix concrete is permitted as per drawing or by the Engineer. Nominal Mix may be permitted only for minor bridges and culverts or other incidental construction where strength requirements are upto M 20 only. Nominal Mix may also be permitted for non-structural concrete or for screed below open foundations. 1703.4. If the Contractor so elects, the Engineer may permit the use of higher grade concrete than that specified on the drawing, in which event the higher grade concrete shall meet the specifications applicable thereto without additional compensation. 1704. PROPORTIONING OF CONCRETE Prior to the start of construction, the Contractor shall design the mix in case of Design Mix Concrete or propose nominal mix in case of Nominal Mix Concrete, and submit to the Engineer for approval, the proportions of materials, including admixtures to be used. Water-reducing admixtures (including plasticisers or super-plasticsers) may be
Signature of Bidder
used at the Contractors option, subject to the approval of the Engineer. Other types of admixtures shall be prohibited, unless specifically permitted by the Engineer. 1704.1. Requirements of Consistency The mix shall have the consistency which will allow proper placement and consolidation in the required position. Every attempt shall be made to obtain uniform consistency. The optimum consistency for various types of structure shall be as indicated in Table 1700-4, or as directed by the Engineer. The slump of concrete shall be checked as per IS : 516. TABLE 1700-4. TYPE 1 (a) Structures with exposed inclined surface requiring low slump concrete to allow proper compaction (b) plain cement concrete RCC structures with widely spaced reinforcements; e.g. solid columns, piers, abutments, footings, well steining RCC structures with fair degree of congestion of reinforcement; e.g. pier and abutment caps, box culverts well curb, walls with thickness greater than 300 mm RCC and PSC structures with highly congested reinforcements e.g deck slab girders, box girders, walls with thickness less than 300 mm Underwater concreting through tremie e.g. bottom plug, cast-in-situ piling 1704.2. Requirements for Designed Mixes 1704.2.1. Target mean strength The target mean strength of specimen shall exceed the specified characteristic compressive strength by at least the current margin. SLUMP(mm) 25 25 40 50
50 75
75 125
100 200
Signature of Bidder
(i)
The current margin for a concrete mix shall be determined by the Contractor and shall be taken as 1.64 times the standard deviation of samples test results taken from at least 40 separate batches of concrete of nominally similar proportions produced at site by the same plant under similar supervision, over a period exceeding 5 days, but not exceeding 6 months.
(ii) Where there is insufficient data to satisfy the above, the current margin for the initial design mix shall be taken as given in Table 1700-5: TABLE 17005. Concrete Grade M 15 M 20 M 25 M 30 M 35 M 40 M 45 M 50 M 55 Current Margin (MPa) 10
10
11 12 12 12 13 13 14
Target Mean Strength (MPa) 25 30 36 42 47 52 58 63 69
The initial current margin given in the Table 1700-5 shall be used till sufficient data is available to determine the current margin as per sub-clause (i) above. 1704.2.2. Trial mixes The Contractor shall give notice to enable the Engineer to be present at the making of trial mixes and preliminary testing of the cubes. The Contractor shall prepare trial mixes, using samples of approved materials typical of those he proposes to use in the works, for all grades to the Engineers satisfaction prior to commencement of concreting. The initial trial mixes shall generally be carried out in an established laboratory approved by the Engineer. In exceptional cases, the Engineer may permit the initial trial mixes to be prepared at the site laboratory of the Contractor, if a full fledged concrete laboratory has been established well before the start of construction, to his entire satisfaction. In all cases complete testing of materials forming the constituents of proposed Design Mix shall have been carried out prior to making trial mixes. Sampling and testing procedures shall be in accordance with these specifications. When the site laboratory is utilised for preparing initial mix design, the concrete plant and means of transport employed to make the trial mixes shall be similar to that proposed to be used in the works.
Signature of Bidder
Test cubes shall be taken from trial mixes as follows. Fir each mix, set of six cubes shall be made from each of three consecutive batches. Three cubes from each set of six shall be tested at an age of 28 days and three at an earlier age approved by the Engineer. The cubes shall be made, cured, stored, transported and tested in accordance with these specifications. The average strength of the nine cubes at 28 days shall exceed the specified characteristic strength by the current margin minus 3.5 MPa. 1704.2.3. Control of strength of design mixes a) Adjustment to Mix Proportions
Adjustments to mix proportions arrived at in the trial mixes shall be made subject to the Engineers approval, in order to minimise the variability of strength and to maintain the target mean strength. Such adjustments shall not be taken to imply any change in the current margin. b) Change of Current Margin
When required by the Engineer, the Contractor shall recalculate the current margin in accordance with Clause 1704.2.1. The recalculated value shall be adopted as directed by the Engineer, and it shall become the current margin for concrete produced subsequently. c) Additional Trial Mixes
During production, the Contractor shall carry out trial mixes and tests, if required by the Engineer, before substantial changes are made in the material or in the proportions of the materials to be used, except when adjustments to the mix proportions are carried out in accordance with sub-clause (a) above. 1704.3. Requirements of Nominal Mix Concrete Requirements for nominal mix concrete unless otherwise specified, shall be as detailed in Table 1700-6. TABLE 1700-6. PROPORTIONS FOR NOMINAL MIX CONCRETE Concrete Grade Total Quantity of dry aggregate by mass per 50 kg of cement to be taken as the sum of individual masses of fine and coarse aggregates (kg) Proportion of fine to Coarse aggregate (by mass)
Signature of Bidder
M 15 M 20
350 250
Generally 1:2, subject to upper limit 1:1.5 and lower limit of 1:1.25
Generally 1:2, subject to upper limit 1:1.5 and lower limit of 1:1.25
1704.4.
Additional Requirements
Concrete shall meet with any other requirements as specified on the drawing or as directed by the Engineer. Additional requirements shall also consist of the following overall limits of deleterious substances in concrete: a) b) 1704.5. The total chloride content of all constituents of concrete as a percentage of mass of cement in mix shall be limited to values given below: Prestressed Concrete Reinforced concrete exposed to chlorides in service (e.g. structures located near sea coast) Other reinforced concrete construction : : : 0.1 per cent 0.2 per cent 0.3 percent
The total sulphuric anhydride (SO3) content of all constituents of concrete as a percentage of mass of cement in the mix shall be limited to 4 per cent. Suitability of Proposed Mix Proportions
The Contractor shall submit the following information for the Engineers approval: a) b) c) Nature and source of each material Quantities of each material per cubic meter of fully compacted concrete Either of the following: (i) appropriate existing data as evidence of satisfactory previous performance for the target mean strength, current margin, consistency and water/cement ratio and any other additional requirement(s) as specified. full details of tests on trial mixes.
(ii) d)
Statement giving the proposed mix proportions for nominal mix concrete.
Signature of Bidder
Any change in the source of material or in the mix proportions shall be subject to the Engineers prior approval. 1705. ADMIXTURES Use of admixtures such as superplasticisers for concrete may be made with the approval of the Engineer. As the selection of an appropriate concrete admixture is an integral part of the mix design, the manufacturers shall recommend the use of any one of his products only after obtaining complete knowledge of all the actual constituents of concrete as well as methodologies of manufacture, transportation and compaction of concrete proposed to be used in the project. 1706. SIZE OF COARSE AGGREGATE The size (maximum nominal) of coarse aggregates for concrete to be used in various components shall be given as Table 1700-7. TABLE 1700-7. Components i) RCC well curb ii) RCC/PCC well steining Maximum Nominal Size of Coarse Aggregate (mm) 20 40 40 20 20 As specified by Engineer
iii) Well cap or Pile Cap Solid type piers and
abutments iv) RCC work in girders, slabs, wearing coat,

piers and piles
kerb, approach slab, hollow abutments, pier/abutment caps,
v) PSC work vi) Any other item
Maximum nominal size of aggregates shall also be restricted to the smaller of the following values: a) b) 10 mm less than the minimum lateral clear distance between main reinforcements 10 mm less than the minimum clear cover to the reinforcements
Signature of Bidder
The proportions of the various individual size of aggregates shall be so adjusted that the grading produces densest mix and the grading curve corresponds to the maximum nominal size adopted for the concrete mix. 1707. EQUIPMENT Unless specified otherwise, equipment for production, transportation and compaction of concrete shall be as under: a) For Production of Concrete: i) For overall bridge length of less than 200 meters - batch type concrete mixer diesel or electric operated, with a minimum size of 200 litres, automatic water measuring system and internal weigher (hydraulic/pneumatic type) ii) For overall bridge length of 200 meters or more - concrete batching and mixing plant fully automatic with minimum capacity of 15 cu. m. per hour. All measuring devices of the equipment shall be maintained in a clean and serviceable condition. Its accuracy shall be checked over the range in use, when set up at each site and thereafter periodically as directed by the Engineer. The accuracy of the measuring devices shall fall within the following limits: D.6.1.31 Measurement of Cement 3 per cent of the quantity of cement in each batch 3 per cent of the quantity of water in each batch
Measurement of Water
Measurement of Aggregate 3 per cent of the quantity of aggregate in each batch Measurement of Admixture 5 per cent of the quantity of admixture in each batch b) For Concrete Transportation : i) Concrete dumpers ii) Powered hoists iii) Chutes iv) Buckets handled by cranes v) Transit truck mixer vi) Concrete pump vii) Concrete distributor booms viii) Belt conveyor ix) Cranes with skips depending upon actual requirement minimum 2 tonnes capacity minimum 0.5 tonne capacity
Signature of Bidder
x)
Tremies size 25 mm to 70 mm minimum 500 watts full width of carriageway (upto two lanes)
c) For Compaction of Concrete: i) Internal vibrators ii) Form vibrators iii) Screed vibrators
1708. MIXING CONCRETE Concrete shall be mixed either in a concrete mixer or in a batching and mixing plant, as per these specifications. Hand mixing shall not be permitted. The mixer or the plant shall be at an approved location considering the properties of the mixes and the transportation arrangements available with the Contractor. The mixer or the plant shall be approved by the Engineer. Mixing shall be continued till materials are uniformly distributed and a uniform colour of the entire mass is obtained, and each individual particle of the coarse aggregate shows complete coating of mortar containing its proportionate amount of cement. In no case shall mixing be done for less than 2 minutes. Mixes which have been out of use for more than 30 minutes shall be thoroughly cleaned before putting in a new batch. Unless otherwise agreed to by the Engineer, the first batch of concrete from the mixer shall contain only two thirds of the normal quantity of coarse aggregate. Mixing plant shall be thoroughly cleaned before changing from one type of cement to another. 1709. TRANPORTION, PLACING AND COMPACTION OF CONCRETE The method of transporting and placing concrete shall be approved by the Engineer. Concrete shall be transported and placed as near as practicable to its final position, so that no contamination, segregation or loss of its constituent materials takes place. Concrete shall not be freely dropped into placed from a height exceeding 1.5 metres. When concrete is conveyed by chute, the plant shall be of such size and design as to ensure practically continuous flow. Slope of the chute shall be so adjusted that the concrete flows without the use of excessive quantity of water and without any segregation of its ingredients. The delivery end of the chute shall be as close as possible to the point of deposit. The chute shall be thoroughly flushed with water before and after each working period and the water used for this purpose shall be discharged outside the formwork.
Signature of Bidder
All formwork and reinforcement contained in it shall be cleaned and made free from standing water, dust, snow or ice immediately before placing of concrete. No concrete shall be placed in any part of the structure until the approval of the Engineer has been obtained. If concreting is not started within 24 hours of the approval being given, it shall have to be obtained again from the Engineer. Concreting then shall proceed continuously over the area between the construction joints. Fresh concrete shall not be placed against concrete which has been in position for more than 30 minutes unless a proper construction joint is formed. Except where otherwise agreed to by the Engineer, concrete shall be deposited in horizontal layers to a compacted depth of not more than 450 mm when internal vibrators are used and not exceeding 300 mm in all other cases.
Concrete when deposited shall have a temperature of not less than 5 degrees Celsius, and not more than 40 degrees Celsius. It shall be compacted in its final position within 30 minutes of its discharge from the mixer, unless carried in properly designed agitators, operating continuously, when this time shall be within 1 hour of the addition of cement to the mix and within 30 minutes of its discharge from the agitator. It may be necessary to add retarding admixtures to concrete if trials show that the periods indicated above are unacceptable. In all such matters, the Engineers decision shall be final. Concrete shall be thoroughly compacted by vibration or other means during placing and worked around the reinforcement, tendons or duct formers, embedded fixtures and into corners of the formwork to produce a dense homogeneous void-free mass having the required surface finish. When vibrators are used, vibration shall be done continuously during the placing of each batch of concrete until the expulsion of air has practically ceased and in a manner that does not promote segregation. Over vibration shall be avoided to minimise the risk of forming a weak surface layer. When external vibrators are used, the design of formwork and disposition of vibrator shall be such as to ensure efficient compaction and to avoid surface blemishes. Vibrations shall not be applied through reinforcement and where vibrators of immersion type are used, contact with reinforcement and all inserts like ducts etc., shall be avoided. The internal vibrators shall be inserted in an orderly manner and the distance between insertions should be about one and a half times the radius of the area visibly affected by vibration. Additional vibrators in serviceable condition shall be kept at site so that they can be used in the event of breakdowns.
Signature of Bidder
Mechanical vibrators used comply with IS: 2502, IS: 2506, IS: 2514 and IS: 4656. 1710. CONSTRUCTION JOINTS Construction joints shall be avoided as far as possible and in no case the locations of such joints shall be changed or increased from those shown on the drawings, except with express approval of the Engineer. The joint shall be provided in a direction perpendicular to the member axis. Location, preparation of surface and concreting of construction joints shall conform to the additional specifications given in Appendix 1700/1. 1711. CONCRETING UNDER WATER When it is necessary to deposit concrete under water, the methods, equipment, materials and proportions of mix to be used shall be got approved from the Engineer before any work is started. Concrete shall contain 10 per cent more cement than that required for the same mix placed in the dry. Concrete shall not be placed in water having a temperature below 5 degrees Celsius. The temperature of the concrete, when deposited, shall not be less than 16 degrees Celsius, nor more than 40 degrees Celsius. Coffer dams or forms shall be sufficiently tight to ensure still water conditions, if practicable, and in any case to reduce the flow of water to less than 3 metres per minute through the space into which concrete is to be deposited. Coffer dams or forms in still water shall be sufficiently tight to prevent loss of mortar through the joints in the walls. Pumping shall not be done while concrete is being placed, or until 24 hours thereafter. To minimise the formation of laitance, great care shall be exercised not to disturb the concrete as far as possible while it is being deposited. All under water concreting shall be carried out by tremie method only, using tremie of appropriate diameter. The number and spacing of the tremies should be worked out to ensure proper concreting. The tremie concreting when started should continue without interruption for the full height of the member being concreted. The concrete production and placement equipment should be sufficient to enable the underwater concrete to be completed uninterrupted within the stipulated time. Necessary stand-by equipment should be available for emergency situation.
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The top section of the tremie shall have a hopper large enough to hold one full batch of the mix or the entire contents of the transporting bucket as the case may be. The tremie pipe shall not be less than 200 mm in diameter and shall be large enough to allow a free flow of concrete and strong enough to withstand the external pressure of the water in which it is suspended, even if a partial vacuum develops inside the pipe. Preferably, flanged steel pipe of adequate strength for the job shall be used. A separate lifting device shall be provided for each tremie pipe with its hopper at the upper end. Unless the lower end of the pipe is equipped with an approved automatic check value, the upper end of the pipe shall be plugged with a wadding of gunny sacking or other approved material before delivering the concrete to the tremie pipe through the hopper, so that when the concrete is forced down from the hopper to the pipe, it will force the plug (and along with it any water in the pipe) down the pipe and out of the bottom end, thus establishing a continuous stream of concrete. It will be necessary to raise slowly the tremie in order to allow a uniform flow of concrete, but it shall not be emptied so that water is not allowed to enter above the concrete in the pipe. At all times after placing of concrete is started and until all the required quantity has been placed, the lower end of the tremie pipe shall be kept below the surface of the plastic concrete. This will cause the concrete to build up from instead of flowing out over the surface and thus avoid formation of layers of laitance. If the charge in the tremie is lost while depositing, the tremie shall be raised above the concrete surface and unless sealed by a check valve, it shall be replugged at the top end, as at the beginning, before refilling for depositing further concrete. 1712. ADVERSE WEATHER CONDITIONS 1712.1. Cold Weather Concreting Where concrete is to be deposited at or near freezing temperature, precautions shall be taken to ensure that at the time of placing, it has a temperature of not less than 5 degrees Celsius and that the temperature of the concrete shall be maintained above 4 degrees Celsius until it has thoroughly hardened. When necessary, concrete ingredients shall be heated before mixing but cement shall not be heated artificially other than by the heat transmitted to it from other ingredients of the concrete. Stock-piled aggregate may be heated by the use of dry heat or steam. Aggregates shall not be heated directly by gas or on sheet metal over fire. In general, the temperature of aggregates or water shall not exceed 65 degrees Celsius. Salt or other chemicals shall not be used for the prevention of freezing. No frozen material or materials containing ice shall be used. All concrete damaged by frost shall be removed. It is recommended that concrete exposed to freezing weather shall have entrained air and the water content of the mix shall not exceed 30 litres per 50 kg of cement. 1712.2. Hot Weather Conditions
Signature of Bidder
When depositing concrete in very hot weather, precautions shall be taken so that the temperature of wet concrete does not exceed 40 degrees Celsius while placing. This shall be achieved by stacking aggregate under the shade and keeping them moist, using cold water, reducing the time between mixing and placing to the minimum, cooling formwork by sprinkling water, starting curing before concrete dries out and restricting concreting as far as possible to early mornings and late evenings. When ice is used to cool mixing water, it will be considered a part of the water in design mix. Under no circumstances shall the mixing operation be considered complete until all ice in the mixing drum has melted. The Contractor will be required to state his methodology for the Engineers approval when temperatures of concrete are likely to exceed 40 degrees Celsius during the work. 1713. PROTECTION AND CURING
Concreting operations shall not commence until adequate arrangements for concrete curing have been made by the Contractor. Curing and protection of concrete shall start immediately after compaction of the concrete to protect it from: a) b) c) d) e) f) Premature drying out particularly by solar radiation and wind High internal thermal gradients Leaching out by rain and flowing water Rapid cooling during the first few days after placing Low temperature or frost Vibration and impact which may disrupt the concrete and interfere with its bond to the reinforcement
Where members are of considerable size and length, with high cement content, accelerated curing methods may be applied, as approved by the Engineer. 1713.1. Water Curing
Signature of Bidder
Water for curing shall be as specified in Section 1000. Sea water shall not be used for curing. Sea water shall not come into contact with concrete members unless it has attained adequate strength. Exposed surfaces of concrete shall be kept continuously in a damp or wet condition by ponding or by covering with a layer of sacks, canvas, Hessian or similar materials and shall be kept constantly wet for a period of not less than 14 days from the date of placing of concrete. 1713.2. Steam Curing Where steam curing is adopted, it shall be ensured that it is done in a suitable enclosure to contain the live stream in order to minimise moisture and heat losses. The initial application of the steam shall be after about four hours of placement of concrete to allow the initial set of the concrete to take place. Where retarders are used, the waiting period before application of the steam shall be increased to about six hours. The steam shall be at 100 per cent relative humidity to prevent loss of moisture and to provide excess moisture for proper hydration of the cement. The application of steam shall not be directly on the concrete and the ambient air temperature shall increase at a rate not exceeding 5 degrees Celsius per hour until a maximum temperature of 60 degrees Celsius to 70 degrees Celsius is reached. The maximum temperature shall be maintained until the concrete has reached the desired strength. When steam curing is discontinued, the ambient air temperature shall not drop at a rate exceeding 5 degrees Celsius per hour until a temperature of about 10 degrees Celsius above the temperature of the air to which the concrete will be exposed, has been reached. The concrete shall not be exposed to temperatures below freezing for at least six days after curing. 1713.3. Curing Compounds Curing compounds shall only be permitted in special circumstances and will require specific approval of the Engineer. Curing compounds shall not be used on any
Signature of Bidder
surface which requires further finishing to be applied. All construction joints shall be moist, cured and no curing compound will be permitted in locations where concrete surface are required to be bonded together. Curing compounds shall be continuously agitated during use. All concrete cured by this method shall receive two applications of the curing compound. The first coat shall be applied immediately after acceptance of concrete finish. If the surface is dry, the concrete shall be saturated with water and curing compound applied as soon as the surface film of water disappears. The second application shall be made after the first application has set. Placement in more than two coats may be required to prevent streaking. 1714. FINISHING
Immediately after the removal of forms, exposed bars or bolts, if any, shall be cut inside the concrete member to a depth of at least 50 mm below the surface of the concrete and the resulting holes filled with cement mortar. All fins caused by form joints, all cavities produced by the removal of form ties other holes and depressions, honeycomb sports, broken edges or corners, and other defects, shall be thoroughly cleaned, saturated with water, and carefully pointed and rendered true with mortar of cement and fine aggregate mixed in the proportions used in the grade of concrete that is being finished and of as dry a consistency as is possible to use. Considerable pressure shall be applied in filling and pointing to ensure thorough filling in all voids. Surfaces which have been pointed shall be kept moist for a period of twenty four hours. Special pre-packaged proprietary mortars shall be used where appropriate or where specified in the drawing. All construction and expansion joints in the completed work shall be left carefully tooled and free from any mortar and concrete. Expansion joint filler shall be left exposed for its full length with clean and true edges. Immediately on removal of forms, the concrete work shall be examined by the Engineer before any defects are made good. a) The work that has sagged or contains honeycombing to an extent detrimental to structural safety or architectural appearance shall be rejected. Surface defect of a minor nature may be accepted. On acceptance of such work by the Engineer, the same shall be rectified as directed by the Engineer. 1715. TOLERANCES
b)
Tolerances for dimensions/shape of various components shall be as indicated in these specifications or shown on the drawings or as directed by the Engineer.
Signature of Bidder
1716. TESTS AND STANDARDS OF ACCEPTANCE 1716.1. Concrete shall conform to the surface finish and tolerance as prescribed in these specifications for respective components. 1716.2. Random sampling and lot by lot of acceptance inspection shall be made for the 28 days cube strength of concrete. 1716.2.1. Concrete under acceptance shall be notionally divided into lots for the purpose of sampling, before commencement of work. The delimitation of lots shall be determined by the following: (i) No individual lot shall more than 30 cu.m. in volume (ii) At least one cube forming an item of the sampling representing the lot shall be taken from concrete of the same grade and mix proportions cast on any day. (iii) Different grades of mixes of concrete shall be divided into separate lots (iv) Concrete of a lot shall be used in the same identifiable component of the bridge 1716.2.2. Sampling and testing 1. Concrete for making 3 test cubes shall be taken from a batch of concrete at point of delivery into construction, according to procedure laid down in IS : 1199. 2. A random sampling procedure to ensure that each of the concrete batches forming the lot under acceptance inspection has equal chance of being chosen for taking cubes shall be adopted. 3. 150 mm cubes shall be made, cured and tested at the age of 28 days for compressive strength in accordance with IS: 516. The 28-day test strength result for each cube shall form an item of the sample. 1716.2.3. Test specimen and sample strength: Three test specimens shall be made from each sample for testing at 28 days. Additional cubes may be required for various purposes such as to determine the strength of concrete at 7 days or for any other purpose. The test strength of the sample shall be the average of the strength of 3 cubes. The individual variation should not be more that + 15 per cent of the average. 1716.2.4. Frequency: The minimum frequency of sampling of concrete of each grade shall be in accordance with Table 1700-8.
Signature of Bidder
TABLE 1700-8. Quality of concrete in work, m3 15 6 15 16 30 31 50 51 and above No. of samples
1 2 3 4 4 plus one additional sample for each additional 50 m3 or part thereof ________________________________________________________________________ At least one sample shall be taken from each shift of work. 1716.2.5. Acceptance criteria Compressive Strength When both the following conditions are met, the concrete complies with the specified compressive strength: a) The mean strength determined from any group of four consecutive samples should exceed the specified characteristic compressive strength. b) Strength of any sample is not less than the specified characteristic compressive strength minus 3 MPa. The quantity of concrete represented by the test results include the batches from which the first and last samples were taken, together with all intervening batches. Chloride and Sulphate Content The total chloride and sulphuric anhydride (SO3) content of all the constituents of concrete as a percentage of mass of cement in the mix shall not exceed the values given in this section of the specifications. 1716.3. Density of Fresh Concrete Where minimum density of fresh concrete is specified, the mean of any four consecutive samples shall not be less than the specified value and any individual sample result shall not be less than 97.5 per cent of the specified value.
Signature of Bidder
1716.4. Density of Hardened Concrete Where minimum density of hardened concrete is specified, the mean of any four consecutive samples shall not be less than the specified value and any individual sample result shall not be less than 97.5 per cent of the specified value. 1716.5. Permeability Test The concrete should pass the following test if it is properly compacted and is not considered permeable. (i) (ii) Prepare a cylindrical test specimen 150 mm diameter and 160 mm high After 28 days of curing, the test specimen is fitted in a machine such that the specimen can be placed in water under pressure up to 7 bars. A typical machine is shown in Appendix 1700/11. At first a pressure of one bar is applied for 48 hours, followed by 3 bars for 24 hours and 7 bars for next 24 hours. After the passage of the above period, the specimen is taken out and split in the middle by compression applied on two round bars on opposite sides above and below. The water penetration in the broken core is to be measured with a scale and the depth of penetration assessed in mm (max. permissible limit 25 mm).
(iii) (iv)
(v)
1716.6. If the concrete is not able to meet any of the standards of acceptance as prescribed, the effect of such deficiency on the structure shall be investigated by the Contractor as directed by the Engineer. The Engineer may accept the concrete as substandard work. Any additional work required by the Engineer for such acceptance shall be carried out by the Contractor at his cost. In case the concrete is not found to be acceptable after investigation, the Contractor shall remove the rejected concrete forthwith. 1717. MEASUREMENTS FOR PAYMENT Structural concrete shall be measured in cubic meters. In reinforced or prestressed concrete, the volume occupied by reinforcement or prestressing cables and sheathing shall not be deducted. The slab shall be measured as running continuously through and the beam as the portion below the slab. 1718. RATE The contract unit rate for structural concrete shall cover costs of all materials, labour, tools, plant and equipment required for mixing, transporting and placing in
Signature of Bidder
position, vibrating and compaction, finishing and curing as per this section or as directed by the Engineer, including all incidental expenses, sampling and testing, quality assurance and supervision. Unless mentioned separately as an item in the Contract, the contract unit rate for concrete shall also include the cost of providing, fixing and removing formwork required for concrete work as per Section 1500. Where concrete is found to be acceptable as sub-standard work, the Contractor shall pay a discount over contract unit rate, as decided by the Engineer. For deficiency in compressive strength of concrete when accepted by the Engineer, the reduction in rate may be applied as under: Design Strength Observed Strength Per cent reduction = ----------------------------------------------------------- X 100 Design Strength
Signature of Bidder
1901. DESCRIPTION This work shall include furnishing, fabricating, transporting, erecting and painting structural steel, rivet steel, cast steel, steel forgings, cast iron and other incidental metal construction of the kind, size and quantity in conformity with the drawings and these specifications or as desired by the Engineer. 1902. GENERAL General requirements relating to the supply of material shall conform to the specifications of IS : 1387, for the purpose of which the supplier shall be the Contractor and the purchaser shall be the Engineer. Finished rolled material shall be free from cracks, flaws, injurious seams, laps, blisters, ragged and imperfect edges and other defects. It shall have a smooth and uniform finish, and shall be straightened in the mill before shipment. They shall also be free from loose mill scale, rust, pits or other defects affecting its strength and durability. The acceptance of any material on inspection at the mill i.e. rolling, mills, foundry or fabricating plant where material for the work is manufactured, shall not be a bar to its subsequent rejection, if found defective. Unless specified otherwise, high tensile steel rivet conforming to IS : 1149 shall be used for members of high tensile steel conforming to IS : 961 and shall not be used for mild steel members. Unless specified otherwise, bolted connection of structural joints using high tensile friction grip bolts shall comply with requirements of IS : 4000. Cast iron shall be used in any portion of the bridge structure, except where it is subject to direct compression. 1903. MATERIALS
1903.1. All materials shall conform to Section 1000. Special requirements are given below: Mild steel for bolts and nuts shall conform to IS : 226 but have a minimum tensile strength of 44 kg/sq. mm. and minimum percentage elongation of 14. High tensile steel for bolts and nuts shall conform to IS : 961 but with a minimum tensile strength of 58 kg/sq. mm. High strength friction grip bolts shall be permitted for use only on satisfactory evidence of performance to the requirements (not covered by these specifications) specified by the Engineer or included in the special provisions. For cast steel, the yield stress shall be determined and shall not be less than 50 per cent of the minimum tensile strength.
Signature of Bidder
Plain washers shall be of steel. Tapered or other specially shaped washers shall be of steel, or malleable cast iron. Parallel barrel drift shall have a tensile strength not less than 55 kg/sq. mm. with elongation of not less than 20 per cent measured on a gauge length of 4 So (So = cross section area). 1903.2. Materials for castings and forgings, fasteners and welding consumables shall be as under: 1903.2.1. Castings and Forgings: Steel castings and forgings shall comply with the requirements of the following Indian Standards, as appropriate: IS : 1030 IS : 1875 IS : 2004 IS : 2644 IS : 4367 Carbon Steel Castings for General Engineering purposes Carbon Steel Billets, blooms, slabs, bars for forgings Carbon Steel Forgings for General Engineering purposes High Tensile Steel Casings Alloy & tool steel forgings for general industrial use
1093.2.2. Fasteners: Bolts, nuts, washers and rivets shall comply with the following or relevant IS Standards as appropriate: IS : 1929 IS : 2155 IS : 1363 IS : 1364 IS : 1367 IS : 3640 IS : 3757 IS : 6623 IS : 6639 Hot forged steel rivets for hot closing (12-36 mm dia) Cold forged steel rivets for hot closing (6-16 mm dia) Hexagon head bolts, screw and nuts product grade C Hexagon head bolts, screw & nuts product grade A & B Technical supply conditions for threaded steel fastener (Part 1 to 18) Hexagon fit bolts High tensile friction grip bolts High strength structural nuts Hexagon bolts for steel structure
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IS : 5624 IS : 7002 IS : 5369 IS : 5370 IS : 5372 IS : 5374 IS : 6610 IS : 6649
Foundation bolts Prevailing torque type steel hexagon lock nuts Plain washers and lock washers general requirements Plain washers with outside dia = 3 X inside dia Taper washers for channel (ISMC) Taper Washers for I beams (ISMB) Heavy washers for steel structures Hardened and tempered washers for high strength structural bolts and nuts
1903.2.3. Welding consumables Welding consumables shall comply with the following Indian Standards as appropriate: IS : 814 (Part 1) IS : 814 (Part 2) IS : 1278 IS : 1395 IS : 3613 IS : 7280 IS : 6419 IS : 6560 Covered Electrodes for Metal Arc Welding of structural steel for welding other than sheet For welding sheets Filler rods and wires for gas welding Low and medium alloy Steel covered electrodes for manual Metal Arc Welding Acceptance Tests for wire flux combinations for sub-merged arc welding of structural steel Bare wire electrodes for gas shield arc welding of structural steel Welding rods and bare electrodes for gas shielded arc welding of structural steel Molybdenum and chromium-molybdenum low alloy steel welding rods and bare electrodes for gas shielded arc welding
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1903.3 In aggressive environment, corrosion resistant steel can be used. These are low-alloyed steels containing a total of 1 per cent 2 per cent alloys, in particular, copper, chromium, nickel and phosphorous. 1093.3. Paints All material for paints and enamels shall conform to the requirements specified on the drawings or other special provisions laid down by the Engineer. The type of paints which can be used shall be as follows: a) Ordinary i.e. paints based on drying oils, alkyd resin, modified alkyd resin, phenolic varnish epoxy b) Chemical Resistant-one pack type (ready for use) and two pack type (mixed before use). c) Vinyl d) Chlorinated rubber e) Bituminous f) Epoxy g) Polyurethane h) Zinc rich Unless otherwise specified, paints shall conform to he relevant IS specifications. The paints which have been tested for the following qualities as per specifications given in the relevant IS codes only shall be used: Weight test (weight for 10 litre of paint, thoroughly mixed) Drying time Consistency Dry thickness and rate of consumption.
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1904. 1904.1. General
FABRICATION
All work shall be in accordance with the drawings and as per these specifications with care being taken that all parts of an assembly fit accurately together. All members shall carry mark number and item number and, if required, serial number. Unless specifically required under the contract, corresponding parts need not be interchangeable, but the parts shall be match marked as required under Clause 1904.7. Templates, jigs and other appliances used for ensuring the accuracy of the work shall be of mild steel; where specially required, these shall be bushed with hard steel. All measurements shall be made by means of steel tape or other device properly calibrated. Where bridge materials have been used as templates for drilling, these shall be inspected and passed by the Engineer before they are used in then finished structure. All structural steel members and parts shall have straight edges and blunt surfaces. If necessary, they shall be straightened or flattened by pressure unless they are required to be of curvilinear forms. They shall also be free from twist. Pressure applied for straightening or flattening shall be such as would not injure the materials. Hammering shall not be permitted. Adjacent surfaces or edges shall be in close contact or at uniform distance throughout. The Contractor shall submit his programme of work to the Engineer for his approval at least 15 days before the commencement of fabrication. This programme shall include the proposed system of identification and erection marks together with complete details of fabrication and welding procedures. The Contractor shall prepare shop drawings for fabricating any member and obtain approval of the Engineer before the start of work. Complete information regarding the location, type, size and extent of all welds shall be clearly shown on the shop drawings. These drawings shall distinguish between shop and field welds. 1904.2. Preparation of Edges and Ends All structural steel parts, where required, shall be sheared, cropped, sawn or flame cut and ground accurately to the required dimension and shape.
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End/edge planing and cutting shall be done by any one of the following prescribed methods or left as rolled: a) b) c) Shearing, cropping, sawing, machining, machine flame cutting. Hand flame cutting with subsequent grinding to a smooth edge. Sheared edges of plate not more than 16 mm thick with subsequent grinding to smooth profile, which are for secondary use such as stiffeners and gussets.
If ends of stiffeners are required to be fitted, they shall be ground, so that the maximum gap over 60 per cent of the contact area does not exceed 0.25 mm. Where flame cutting or shearing is used, at least one of the following requirements shall be satisfied. a) b) c) d) e) f) The cut edge is not subject to applied stress. The edge is incorporated in weld. The hardness of cut edge does not exceed 350 HV30. The material is removed from edge to the extent of 2mm or minimum necessary, so that the hardness is less than 350 HV 30. Edge is suitably heat treated by approved method to the satisfaction of the Engineer and shown that cracks had not developed by dye penetrant or magnetic particle test. Thickness of plate is less than 40 mm for machine flame cutting for materials conforming to IS : 226 and IS : 2062. The requirement of hardness of hardness below 350 HV 30 of flame cut edges should be specified by the Engineer.
Wherever specified by the Engineer, the flame cut edges shall be ground or machined over and above the requirement (a) to (f). Where machining for edge preparation in butt joint is specified, the ends shall be machined after the members have been fabricated. Outside edges of plate and section which are prone to corrosion shall be smoothed by grinding or filing. In the case of high tensile steel at least 6 mm of the material from the flame cut edge shall be removed by machining.
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Longitudinal edges of all plates and cover plates in plate girders and built-up members shall be machined except in the following cases: a) b) c) d) e) Rolled edges of single universal plates or flats may not be machined. Covers to single flange plates may be left unmachined. Machine flame cutting instead of machining is acceptable for edges of single plates in compression and for edges of single plates, 25 mm or less thick, in tension. Edges of single shaped plates over 25 mm thick not capable of being machined by ordinary method may be machine flame cut and the end surface ground. Edges of universal plates or flats of the same nominal width used in tiers may be left unmachined, if so authorised by the Engineer.
All edges of splice and gusset plates 12mm thick and over shall be machined and those less than 12 mm thick may be sheared and ground. The ends of plates and sections forming the main components of plate girders or of built-up member shall be machined, machine flame cut, sawn or hand flame cut and ground. Where ends of stiffeners are required to be fitted, they shall be machined, machine flame cut, sawn, sheared and ground, or hand flame cut and ground. The ends of lacing bar shall be rounded unless otherwise required . Other edges and ends of mild steel parts may be sheared and any burrs at edges shall be removed. 1904.3. Preparation of Holes 1904.3.1. Drilling and punching: Holes for rivets, black bolts, high strength bolts and countersunk bolts/rivets (excluding close tolerance and turn fitted bolts) shall be either punched or drilled. The diameter of holes shall be 1.5 mm larger for bolts/rivets less than 25 mm dia and 2.0 mm for more than or equal to 25 mm. All holes shall be drilled except for secondary members such as, floor plate, hand rails etc. Members which do not carry the main load can be punched subject to the thickness of member not exceeding 12 mm for material conforming to IS : 226. Holes through more than one thickness of material or when any of the main material thickness exceeds 20 mm for steel conforming to IS : 961, IS : 8500 shall either be sub-drilled or sub-punched to a diameter of 3 mm less than the required size and then reamed to the required size. The reaming of material more than one thickness shall be done after assembly.
Signature of Bidder
Where several plates or sections form a compound member, they shall, where practicable, be firmly connected together by clamps or tacking bolts, and the holes be drilled through the group in one operation. Alternatively, and in case of repetition work, the plates and sections may be drilled separately from jigs and templates. Jigs and templates shall be checked at least once after every 25 operations. All burrs shall be removed. In case of repetition of spans, the erection of every span shall not be insisted upon, except where close tolerance or turned bolts are used, provided that methods are adopted to ensure strict interchangeability. In such cases, one span in ten or any number less than ten of each type shall be erected from pieces selected at random by the Engineer and should there be any failure of the pieces to fit, all similar spans shall be erected complete. In the event of spans being proved completely interchangeable, all corresponding parts shall carry the same mark so that sorting of the materials at site is facilitated. 1904.3.2. Block drilling: Where the number of plates to be riveted exceeds three or the total thickness is 90 mm or more, the rivet holes, unless they have been drilled through steel bushed jigs, shall be drilled out in place 3 mm all round after assembling. In such cases, the work shall be thoroughly bolted together . 1904.3.3. Size of holes : The sizes of holes in millimetres are given in Table 1900-1 below: TABLE 1900-1 : DIAMETER OF HOLES FOR RIVETS Nominal dia of Rivets (mm) 12 14 16 18 20 22 24 27 30 33 Dia of Holes (mm) 13.5 15.5 17.5 19.5 21.5 23.5 25.5 29.0 32.0 35.0
1904.3.4. Close tolerance bolts and barrel bolts: Holes for close tolerance and turn fitted bolts. The diameter of the holes shall be equal to the nominal diameter of the bolt shank minus 0.15 mm to 0.0 mm.
Signature of Bidder
The members to be connected with close tolerance or turn fitted bolts shall be firmly held together by service bolts or clamped and drilled through all thicknesses in one operation and subsequently reamed to required size within specified limit of accuracy as specified in IS : 919 tolerance grade H8. The holes not drilled through all thicknesses at one operation shall be drilled smaller size and reamed after assembly. 1904.3.5. Holes for high strength friction grip bolts: All holes shall be drilled after removal of burrs. Where the number of plies in the grip does not exceed three, the diameters of holes shall be 1.6 mm larger than those of bolts and for more than three plies in grip, the diameters of hole in outer plies shall be as above and dia of holes in inner plies shall be not be less than 1.6 mm and not more than 3.2 mm larger than those in bolts, unless otherwise specified by the Engineer. 1904.3.6. Removal of burrs: The work shall be taken apart after drilling and all burrs left by drilling and the sharp edges of all rivet holes completely removed. 1904.4. Rivet and Riveting The diameter of rivets shown on the drawings shall be the size before heating. Each rivet shall be of sufficient length to form a head of the standard dimensions as given in IS handbook on Steel Sections, Part I. It shall be free from burrs on the underside of the head. When countersunk heads are required, the heads shall fill the countersunk. The included angle of the head shall be as follows: a) b) For plates over 14 mm thickness For plates upto and including 14 mm thickness 90 degrees 120 degrees
The tolerance on the diameter of rivets shall be in accordance with IS : 1148 and IS : 1149 for mild steel rivets and high tensile steel rivets respectively and unless otherwise specified, the tolerance shall be minus tolerance. Rivets shall be driven when hot so as to fill the hole as completely as possible and shall be of sufficient length to form a head of standard dimension. When counter-sunk head is required, the head shall fill the counter-sunk hole. Projection after counter-sinking shall be ground off wherever necessary. Rivets shall be heated uniformly to a light cherry red colour between 650 degrees Celsius to 700 degrees Celsius for hydraulic riveting and orange colour for pneumatic riveting of mild steel rivets and shall be red hot from head to the point when inserted and shall be upset in its entire length so as to fill the hole as completely as possible when hot. Rivets, after being heated and before being inserted in the hole shall
Signature of Bidder
be made free from scale by striking the hot rivet on a hard surface. Wherever possible, the rivets shall be machine driven, preferably by direct acting riveters. The driving pressure shall be maintained on the rivets for a short time after the upsetting is completed. High tensile steel rivets shall be heated upto 110 degrees Celsius. Any rivet whose point is heated more than prescribed, shall not be driven. off. Where flush surface is required, any projecting metal shall be chipped or ground
Before riveting is commenced, all work shall be properly bolted up so that the various sections and plates are in close contact throughout. Drifts shall only be used for drawing the work into position and shall not be used to such an extent as to distort the holes. Drifts of a larger size than the nominal diameter of the hole shall not be used. The riveting shall be done by hydraulic or pneumatic machine unless otherwise specified by the Engineer. Driven rivets, when struck sharply on the head by a quarter pound rivet testing hammer, shall be free from movement and vibrations. Assembled riveted joint surfaces, including those adjacent to the rivet heads, shall be free from scale, dirt, lose scale, burrs, other foreign materials and defects that prevent solid seating of parts. All loose or burnt rivets with cracked or badly formed defective heads or with heads which are unduly eccentric with the shanks, shall be removed and replaced. In removing rivets, the head shall be sheared off and the rivet punched out so as not to injure the adjacent metal and, if necessary, they shall be drilled out. Recupping or recaulking shall not be permitted. The parts not completely riveted in the shop shall be secured by bolts to prevent damage during transport and handling. 1904.5. Bolts, Nuts and Washers 1904.5.1. Black bolts (black all over): Black bolts are forged bolts in which the shanks, heads and nuts do not receive any further treatment except cutting of screw threads. They shall be true to shape and size and shall have the standard dimensions as shown on the drawings. 1904.5.2. Close tolerance bolts: Close tolerance bolts shall be faced under the head and turned on the shank. 1904.5.3. Turned barrel bolts: The diameter of the screwed portion of turned barrel bolts shall be 1.5 mm smaller than the diameter of the barrel unless otherwise specified by the Engineer. The diameter of the bolts as given on the drawing shall be the nominal diameter of the barrel. The length of the barrel shall be such that it bears fully on all the parts connected. The threaded portion of each bolt shall project through the nut by at least one thread. Faces of heads and nuts bearing on steelwork shall be machined.
Signature of Bidder
1904.5.4. High strength friction bolts and bolted connections: The general requirement shall be as per relevant IS specifications mentioned in clause 5.3. of (Fasteners) of IRC : 24. Unless otherwise specified by the Engineer, bolted connections of structural joints using high tensile friction grip bolts shall comply with requirements in IS : 4000. 1904.5.5. Washers: In all cases where the full bearing area of the bolt is to be developed, the bolt shall be provided with a steel washer under the nut of sufficient thickness to avoid any threaded portion of the bolt being within the thickness of the parts bolted together and to prevent the nut when screwed up, from bearing on the bolt. For close tolerance or turned barrel bolts, steel washers whose faces give a true bearing shall be provided under the nut. The washer shall have a hole diameter not less than 1.5 mm larger than the barrel and a thickness of not less than 6 mm so that the nut when screwed up, will not bear on the shoulder of the bolt. Taper washers with correct angle of taper shall be provided under all heads and nuts bearing on bevelled surfaces. Spring washers may be used under nuts to prevent slackening of the nuts when excessive vibrations occur. Where the heads or nuts bears on timber, square washers having a length of each side not less than three times the diameter of bolts or round washers having a diameter of 3 times the diameter of bolts and with a thickness not less than one quarter of diameter shall be provided. 1904.5.6. Studs: Ordinary studs may be used for holding parts together, the holes in one of the parts being tapped to take the thread of the stud. Counter-sunk studs may be used for making connections where the surfaces are required to be clear of all obstruction, such as protruding heads of bolts or rivets, studs may also be welded on the steel work in the position required. 1904.5.7. Service bolts: Service bolts shall have the same clearance as black bolts and where it is required that there should be no movement prior to final riveting, sufficient drifts or close tolerance bolts shall be used to locate the work. 1904.5.8. Tightening bolts: Bolted connection joints with black bolts and high strength bolts shall be inspected for compliance of codal requirements. The Engineer shall observe the installation and tightening of bolts to ensure that correct tightening procedure is used and shall determine that all bolts are tightening. Regardless of tightening method used, tightening of bolts in a should commence at the most rigidly fixed or stiffest point and progress towards the free edges, both in initial
Signature of Bidder
snuggling and in final tightening. The tightness of bolts in connection shall be checked by inspection wrench, which can be torque wrench, power wrench or calibrated wrench. Tightness of 10 per cent bolts, but not less than two bolts, selected at random in each connection shall be checked by applying inspection torque. If no nut or bolt head is turned by this application, connection can be accepted as properly tightened, but if any nut or head has turned all bolts shall be checked and, if necessary, re-tightened. 1904.5.9. Drifts: The barrel shall be drawn or machined to the required diameter for a length of not less than one diameter over the combined thickness of the metal through which the drifts have to pass. The diameter of the parallel barrel shall be equal to the nominal diameter of the hole subject to a tolerance of +0 mm and 0.125 mm. Both ends of the drift for a length equal to 1 times the diameter of the parallel portion of the bar shall be turned down with a taper to a diameter at the end equal to one-half that of parallel portion. 1904.6.Pins and Pin Holes 1904.6.1. Pins: The pins shall be parallel throughout and shall have a smooth surface free from flaws. They shall be of sufficient length to ensure that all parts connected thereby shall have a full bearing on them. Where the ends are threaded, they shall be turned to a smaller diameter at the ends for the thread and shall be provided with a pilot nut, where necessary, to protect the thread when being drawn to place. Pins more than 175 mm in length or diameter shall be forged and annealed. 1904.6.2. Pin holes: Pin holes shall be bored true to gauge, smooth, straight at right angles to the axis of the member and parallel with each other, unless otherwise required. The tolerance in the length of tension members from outside to outside of pin holes and of compression members from inside to inside of pin holes shall be one millimetre. In built-up members, the boring shall be done after the members have been riveted or welded. The specified diameter of the pin hole shall be its minimum diameter. The resulting clearance between the pin and the hole shall not be less than 0.5 mm and not more than 1.0 mm. 1904 .7. Shop Erection and Match Marking Before being dispatched, the steel work shall be temporarily erected in the fabrication shop for inspection by the Engineer either wholly or in such portion as the Engineer may require so that he may be satisfied both in respect of the alignment and fit of all connections. For this purpose, sufficient number of parallel drifts and service bolts
Signature of Bidder
tightly screwed up shall be employed. All parts shall fit accurately and be in accordance with drawing and specifications. The steel work shall be temporarily assembled at place of fabrication. Assembly shall be of full truss or girder, unless progressive truss or girder assembly, full chord assembly, progressive chord assembly or special complete structure assembly is specified by the Engineer. The field connections of main members of trusses, arches, continuous beams, spans, bends, plate girders and rigid frame assembled, aligned, accuracy of holes and camber shall be checked by Engineer and then only reaming of sub-size holes to specified size shall be taken up. After the work has been passed by the Engineer and before it is dismantled, each part shall be carefully marked for re-erection with distinguishing marks and stamped with durable markings. Drawings showing these markings correctly shall be supplied to the Engineer. Unloading, handling and storage of steel work as per these specifications shall be the responsibility of the Contractor. The cost of repairs or of rejected material, its removal and the cost of transporting replacement material to the site shall be borne by the Contractor. Where close tolerance or turned barrel bolts are used for those cases where interchangeability is not insisted upon, each span shall be erected and members of each span marked distinctly. 1904.8. Welding 1904.8.1. All welding shall be done with the prior approval of the Engineer and the workmanship shall conform to the specifications of IS : 823 or other relevant Indian Standards as appropriate. When material thickness is 20 mm or more, special precautions like preheating shall be taken as laid down in IS : 823. Surfaces and edges to be welded shall be smooth, uniform and free from fins, tears, cracks and other discontinuities. Surface shall also be free from loose or thick scale, slag rust, moisture, oil and other foreign materials. Surfaces within 50 mm of any weld location shall be free from any paint or other material that may prevent proper welding or cause objectionable fumes during welding. The general welding procedures including particulars of the preparation of fusion faces for metal arc welding shall be carried out in accordance with IS : 9595.
Signature of Bidder
The welding procedures for shop and site welds including edge preparation of fusion faces shall be submitted in writing in accordance with Clause 22 of IS : 9595 for the approval of the Engineer before commencing fabrication and shall also be as per details shown on the drawings. Any deviation from above has to approved by Engineer. Preparation of edges shall, wherever practicable, be done by machine methods. Machine flame cut edges shall be substantially as smooth and regular as those produced by edge planing and shall be left free of slag. Manual flame cutting shall be permitted by the Engineer only where machine cutting is not practicable. Electrodes to be used for metal arc welding shall comply with relevant IS specifications mentioned in IRC : 24. Procedure test shall be carried out as per IS : 8613 to find out suitable wire-flux combination for welded joint. Assembly of parts for welding shall be in accordance with provisions of IS : 9595. The welded temporary attachment should be avoided as far as possible, otherwise the method of making any temporary attachment shall be approved by the Engineer. Any scars from temporary attachment shall be removed by cutting, chipping and surface shall be finished smooth by grinding to the satisfaction of the Engineer. Welding shall not be done when the air temperature is less than 10 degrees Celsius. Welding shall not be done when the surfaces are moist, during periods of strong winds or in snowy weather unless the work and the welding operators are adequately protected. 1904.8.2. For welding of any particular type of joint, welders shall qualify to the satisfaction of the Engineer in accordance with appropriate welders qualification as prescribed in any of the Indian Standards IS : 817, IS : 1966, IS : 1393, IS :7307 (part I), IS : 7310 (Part I) and IS : 7318 (part I) as relevant. 1904.8.3.In assembling and joining parts of a structure or of built-up members, the procedure and sequence of welding shall be such as to avoid distortion and minimise shrinkage stress. All requirements regarding pre-heating of parent material and interpass temperature shall be in accordance with provision of IS : 9595. 1904.8.4. Peening of weld shall be carried out wherever specified by the Engineer: a) b) If specified, peening may be employed to be effective on each weld layer except first. The peening should be carried out after weld has cooled by light blows from a power hammer using a round nose tool. Care shall be taken to
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prevent scaling or flaking of weld and base metal from over peening. 1904.8.5. Where the Engineer has specified the butt welds are to be ground flush, the loss of parent metal shall not be greater than that allowed for minor surface defects. The ends of butt joints shall be welded so as to provide full throat thickness. This may be done by use of extension pieces, cross runs or other means approved by the Engineer. Extension pieces shall be removed after the joint has cooled and the ends of the weld shall be finished smooth and flush with the faces of the abutting parts. The joints and welds listed below are prohibited type, which do not perform well under cyclic loading. a) b) c) d) e) f) Butt joints not welded throughout their cross-section Groove welds made from one side only without any backing grip Intermitted groove welds Intermittent fillet welds Bevel-grooves and J-grooves in butt joints for other than horizontal position. Plug and slot welds
1904.8.6. The run-on and run-off plate extension shall be used providing full throat thickness at the end of butt welded joints. These plates shall comply with the following requirements. (i) One pair of run-on and one pair of run-off plates from same thickness and profile as the parent metal shall be attached to start and finish of all butt welds preferably by clamps. When run-on and run-off plates shall be removed by flame cutting, it should be cut at more than 3 mm from parent metal and remaining metal shall be removed by grinding or by any other method approved by the Engineer.
(ii)
1904.8.7. Welding of stud shear connectors: The stud shear connectors shall be welded in accordance with the manufacturers instructions including preheating. The stud and the surface to which studs are welded shall be free from scale, moisture, rust and other foreign material. The stud base shall not be painted, galvanised or cadmium plated prior to welding. Welding shall not be carried out when temperature is below 10 degrees Celsius or surface is wet or during periods of strong winds unless the work and the welder is adequately protected.
Signature of Bidder
The welds shall be visually free from cracks and shall be capable of developing at least the nominal ultimate strength of studs. The procedural trial for welding the stud shall be carried out when specified by the Engineer. 1904.9. Tolerances Tolerances in dimensions of components of fabricated structural steel work shall be specified on the drawings and shall be subject to the approval of the Engineer before fabrication. Unless specified, all parts of an assembly shall fit together accurately within tolerances specified in Table 1900-2. A machined bearing surface, where specified by the Engineer, shall be machined within a deviation of 0.25 mm for surfaces that can be inscribed within a square of side 0.5 m.
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TABLE 1900-2. FABRICATION TOLERANCES A. INDIVIDUAL COMPONENTS 1. Length a) Member with both ends finished for contact bearing b) Individual components of members with end plate connection c) Other members (i) Upto and including 12 M (ii) Over 12 M 2. Width a) Width of built-up girders b)Deviation in the width of members required to be inserted in other members 3. Depth Deviation in the depths of solid web and open web girders 4. Straightness a) Deviation from columns i) In elevation straightness
1 mm + 0 mm - 2 mm 2 mm 3.5 mm 3 mm + 0 mm - 3 mm + 3 mm - 2 mm
of L/3000 subject to a maximum of 15 mm where L is length of member + 5 mm - 0 mm ii) In plan L/1000 subject to a maximum of 10 mm 5. Deviation of centre line of web from centre 3 mm line of flanges in built-up members at contact surfaces 6. Deviation from flatness of plate of webs of 0.005 d to a maximum of 2 mm where d is built-up members in a length equal to depth of the member the depth of the member 7.Tilt of flange of plate girders a) At splices and stiffeners, at supports, at 0.005 b to a minimum of 2 mm where b is the top flanges of plate girders and at width of the member bearings b) at other places 0.015 b to a maximum of 4 mm where b is width of the member 8. Deviation from squareness of flange to L/1000, where L is nominal length of the web of columns and box girders diagonal 9. Deviation from squareness of fixed base D/500, where D is the distance from the plate (not machined) to axis of column. column axis to the point under consideration
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This dimension shall be measured parallel to the longitudinal axis of the column at points where the outer surfaces of the column sections make contact with the base plate 10. Deviation from squareness of machined ends to axes of columns 11. Deviation from squareness of machined ends to axes of beams or girder 12. Ends of members abutting at joints through cleats or end plates, permissible deviation from squareness of ends
on the base plate
D/1000, where D is as defined in 9 above D/1000, where D is as defined in 9 above 1/600 of depth of member subject to a maximum of 1.5 mm
1905. ERECTION 1905.1. General The provisions of this item shall apply to erection of steel bridge superstructures or main members of bridge superstructures, composed of steel, which span between supports. If the sub-structure and the superstructure are built under separate contracts, the department will provide the substructure, constructed to correct lines, dimensions and elevations properly finished and will establish the lines and the elevation required for setting steel. The Contractor shall erect the structural steel, remove the temporary construction, and do all work required to complete the construction included in the contract in accordance with the drawings and the specifications and to the entire satisfaction of the Engineer. 1905.2. Organisation and Equipment The Contractor shall submit erection plans prepared by the fabricator, showing a method and procedure of erection, compatible with the details of fabrication. A detailed scheme must be prepared showing stage-wise activities, with complete drawings and working phase-wise instructions. This should be based on detailed stagewise calculation and take into account specifications and capacity of erection equipment machinery, tools, tackles to be used and temporary working loads as per Codal provisions.
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The scheme should be based on site conditions e.g. hydrology, rainfall, flood timings and intensity, soil and sub-soil conditions in the river bed and banks, maximum water depth, temperature and climatic conditions and available working space, etc. The scheme should indicate precisely the type of temporary fasteners to be used as also the minimum percentage of permanent fasteners to be fitted during the stage erection. The working drawings should give clearly the temporary jigs, fixtures, clamps, spacer supports, etc. Unless otherwise provided in the contract, the contractor shall supply and erect all necessary falsework and staging and shall supply all labour, tools, erection plant and other materials necessary to carry out the work complete in all respects. The Contractor shall supply all rivets, bolts, washers, etc. required to complete erection at site with an allowance for wastage, etc., of 12 per cent of the net number of field rivets, bolts, washers required, or a minimum of five number of each item. Service bolts and nuts, ordinary platters, washers and drifts for use in the erection of work shall be supplied at 60 per cent (45 per cent bolts and 15 per cent drifts) of the number of field rivets per span in each size (this includes wastage). A reduction in the quantities of service bolts, etc., may however, be specified by the Engineer if more than one span of each type is ordered. Prior to actual commencement of erection all equipment, machinery, tools, tackles, ropes, etc. need to be tested to ensure their efficient working. Frequent visual inspection is essential in vulnerable areas to detect displacements, distress, drainages, etc. Deflection and vibratory tests shall be conducted in respect of supporting structures, launching truss as also the structure under erection and unusual observation reviewed; looseness of fittings are to be noted. For welded structures, welders qualifications and skill are to be checked as per standard norms. Non-destructive tests of joints as per designers directives are to be carried out. Precision non-destructive testing instruments available in the market should be used for noting various important parameters of the structures frequently and systematic record is to be kept. Safety requirements should conform to IS : 7205, IS : 7223 and IS : 7269 as applicable and should be a consideration of safety, economy and rapidity. Erection work should start with complete resources mobilised as per latest approved drawings and after a thorough survey of foundations and other related structural work. In case of work of magnitude, maximum mechanisation is to be adopted.
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The structure should be divided into erectable modules as per the scheme. This should be pre-assembled in a suitable yard/platform and its matching with members of the adjacent module checked by trial assembly before erection. The structure shall be set out to the required lines and levels. The stocks and masses are to be carefully preserved. The steelwork should be erected, adjusted and completed in the required position to the specified line and levels with sufficient drifts and bolts. Packing materials are to available to maintain this condition. Organised Quality Surveillance checks need to be exercised frequently. Before starting work, the Contractor shall obtain necessary approval of the Engineer as to the method adopted for erection, the number and character of tools and plants. The approval of the Engineer shall not relieve the Contractor of his responsibility for the safety of his method or equipment or from carrying out the work fully in accordance with the drawing and specifications. During the progress of work, the Contractor shall have a competent Engineer or foreman in charge of the work, who shall be adequately experienced in steel erection and acceptable to the Engineer. 1905.3. Handling and Storing of Materials Suitable area for storage of structures and components shall be located near the site of work. The access road should be free from water logging during the working period and the storage area should be on levelled and firm ground. The store should be provided with adequate handling equipments e.g. road mobile crane, gantries, derricks, chain pulley blocks, winch of capacity as required. Stacking area should be planned and have racks, stands sleeper, access tracks, etc., and properly lighted. Storage should be planned to suit erection work sequence and avoid damage or distortion. Excessively rusted, bent or damaged steel shall be rejected. Methods of storage and handling steel, whether fabricated or not shall be subject to the approval of the Engineer. Fabricated materials are to be stored with erection marks visible, such as not to come contract with earth surface or water and should be accessible to handling equipment. Small fitting hand tools are to be kept in containers in covered stores.
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All materials, consumables, including raw steel or fabricated material shall be stored specification-wise and size-wise above the ground upon platforms, skids or other supports. It shall be kept free from dirt and other foreign matter and shall be protected as far as possible from corrosion and distortion. The electrodes shall be stored specificationwise and shall be kept in dry warm condition in properly designed racks. The bolts, nuts, washers, and other fasteners shall be stored on racks above the ground with protective oil coating in gunny bags. The paint shall be stored under cover in air-tight containers. IS : 7293 and IS : 7969 dealing with handling of materials and equipments for safe working should be followed. Safety nuts and bolts as directed are to be used while working. The Contractor shall be held responsible for loss or damage to any material paid for by the Department while in his care or for any damage to such material resulting from his work. 1905.4. Formwork The formwork shall be properly designed, substantially built and maintained for all anticipated loads. The Contractor, if required, shall submit plans for approval to the Engineer. Approval of the plans, however, shall not relieve the Contractor of his responsibility. 1905.5. Straightening Bent Material The straightening of plates, angles and other shapes shall be done by methods not likely to produce fracture or any injury. The metal shall not be heated unless permitted by the Engineer for special cases, when the heating shall not be to a temperature higher than that producing a dark cherry red colour, followed by as slow cooling as possible. Following the straightening of a bend or buckle the surface shall be carefully investigated for evidence of fracture. Sharp kinks and bends may be the cause for rejection of material. 1905.6. Assembling Steel The parts shall be accurately assembled as shown on the drawings and match marks shall be followed. The material shall be carefully handled so that no parts will be bent, broken or otherwise damaged. Hammering which will injure or distort the members shall not be done. Bearing surface or surfaces to be in permanent contact shall be cleaned, before the members are assembled. The truss spans shall be erected on blocking, so placed as to give the proper camber. The blocking shall be left in place until the tendon chord splices are fully riveted and all other truss connections pinned and bolted. Rivets in splices of butt joints of compression members and rivets in railings shall not be driven until the span has been swung.
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All joint surface for bolted connections including bolts, nuts, washers shall be free from scale, dirt, burrs, other foreign materials and defects that would prevent solid seating of parts. The slope of surface of bolted parts in contact with bolt head and nut shall not exceed 1 in 20, plane normal to bolt axis, otherwise suitable tapered washer shall be used. All fasteners shall have a washer under nut or bolt head whichever is turned in tightening. Any connection to be riveted or bolted shall be secured in close contact with service bolts or with a sufficient number of permanent bolts before the rivets are driven or before the connections are finally bolted. Joints shall normally be made by filling not less than 50 per cent of holes with service bolts and barrel drifts in the ratio 4:1. The service bolts are to be fully tightened up as soon as the joint is assembled. Connections to be made by close tolerance or barrel bolts shall be completed as soon as practicable after assembly. Any connection to be site welded shall be securely held in position by approved methods to ensure accurate alignment, camber and elevation before welding is commenced. The field riveting, welding, bolted and pin connection shall conform to the requirements of Clause 1904 as appropriate. The correction of minor misfits involving harmless amounts of reaming, cutting and chipping will be considered a legitimate part of erection. However, any error in the shop fabrication or deformation resulting from handling and transportation which prevents proper assembling and fitting up of parts by moderate use of drifts or by a moderate amount of reaming and slight chipping or cutting shall be reported immediately to the Engineer and his approval of the method of correction obtained. The correction shall be made in the presence of the Engineer. 1905.7. Field Inspection 1905.7.1. General All materials, equipment and work of erection shall be subject to the inspection of the Engineer who shall be provided with all facilities including labour and tools required at all reasonable times. Any work found defective is liable to be rejected . 1905.7.2. No protective treatment shall be applied to the work until the appropriate inspection and testing has been carried out. The stage inspection shall be carried out for all operations so as to ensure the correctness of fabrication and good quality. Girder dimensions and camber shall not be finally checked until all welding and heating operations are completed and the member has cooled to a uniform temperature.
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1905.7.3. Testing of material: Structural steel shall be tested for mechanical and chemical properties as per various IS codes as may be applicable and shall conform to requirements specified in IS : 226, IS : 2062, IS : 11587, IS : 977, IS : 8500 and IS : 961, etc. Rivets, bolts, nuts, washers, welding consumables, steel forging, casting and stainless steel shall be tested for mechanical and chemical properties in the appropriate IS Code. Rolling and cutting tolerance shall be as per IS : 1852. The thickness tolerance check measurements for the plate and rolled sections shall be taken at not less than 15 mm from edge. Laminations in plates shall be carried out by ultra-sonic testing or any other specified methods. Steel work shall be inspected for surface defects and exposed edge laminations during fabrication and blast cleaning. Significant edge laminations found shall be reported to the Engineer for his decision. Chipping, grinding, machining or ultrasonic testing shall be used to determine depth of imperfection. 1905.7.4. Bolted connections: Bolts and bolted connection joints with high strength friction grip bolts shall be inspected and tested according to IS : 4000. Rivets and riveted connection shall be inspected and tested for compliance of codal requirements. The firmness of joint shall be checked by 0.2 mm filler gauge, which shall not go inside under the rivet head by more than 3 mm. There shall not be any gap between members to be riveted. Driven rivets shall be checked with rivet testing hammer. When struck sharply on head with rivet testing hammer, rivet shall be free from movement and vibration. All loose rivets and rivets with cracks, badly formed or deficient heads or with heads which are eccentric with shanks, shall be cut out and replaced. The alignment of plates at all bolted splice joints and welded butt joints shall be checked for compliance with codal requirements.
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Testing of flame cut and sheared edges is to be done, where the hardness criteria given in the code are adopted. Hardness testing shall be carried out on six specimens. 1905.7.5. Welding and welding consumables: Welding procedure, welded connection and testing shall be in compliance with codal requirements. All facilities necessary for stage inspection during welding and on completion shall be provided to the Engineer or their inspecting Authority by manufacturer. Adequate means of identification either by identification mark or other record shall be provided to enable each weld to be traced to the welder(s) by whom it was carried out. All metal arc welding shall be in compliance with IS : 9595 provisions. The method of inspection shall be in accordance with IS : 822 and extent of inspection and testing shall be in accordance with the relevant standards or in the absence of such a standard, as agreed with the Engineer. Procedure tests The Destructive and Non-Destructive test of weld shall be carried out according to IS : 7307 (Part I). Non-Destructive Testing of Welds weld: One or more of the following methods may be applied for inspection or testing of (i) Visual Inspection: All welds shall be visually inspected, which should cover all defects of weld such as size, porosity, crack in the weld or in the HAZ (Heat Affected Zone) etc. Suitable magnifying glass may be used for visual inspection. A weld shall be acceptable by visual inspection if it shows that: a) The weld has no cracks. b) Through fusion exists between weld and base metal and between adjacent layers of weld metal. c) Weld profiles are in accordance with requisite clauses of IS : 9595 or as agreed with the Engineer.
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d) The weld shall be of full cross section, except for the ends of intermittent fillet welds outside their effective length. e) When weld is transverse to the primary stress, undercut shall not be more than 0.25 mm deep in the part that is undercut and shall not be more than 0.8 mm deep when the weld is parallel to the primary stress in the part that is undercut. f) The fillet weld in any single continuous weld shall be permitted to under run the nominal fillet weld size specified by 1.6 mm without correction provided that undersize portion of the weld does not exceed 10 per cent of the length of the weld. On the web-to-flange weld on girders, no under run is permitted at the ends for a length equal to twice the width of the flange. g) The piping porosity in fillet welds shall not exceed one in each 100 mm of weld length and the maximum diameter shall not exceed 2.4 mm, except for fillet welds connecting stiffeners to web where the sum of diameters of piping porosity shall not exceed 9.5 mm in any 25 mm length of weld and shall not exceed 19 mm in any 300 mm length of weld. h) The full penetration groove weld in butt joints transverse to the direction of computed tensile stress shall have no piping porosity. For all other groove welds, the piping porosity shall not exceed one in 100 mm of length and the maximum diameter shall not exceed 2.4 mm. (ii) Magnetic Particle and Radiographic Inspection: Welds that are subject to radiographic or magnetic particle testing in addition to visual inspection shall have no crack. Magnetic particle test shall be carried out for detection of crack and other discontinuity in the weld according to IS : 5334. Radiographic test shall be carried out for detection of internal flaws in the weld such as crack, piping porosity inclusion, lack of fusion, incomplete penetration, etc. This test may be carried out as per IS : 1182 and IS : 4853. Acceptance Criteria: The weld shall be unacceptable if radiographic or magnetic particle testing shows any of the type of discontinuities indicated in the code.
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(iii)
Ultrasonic Inspection: The Ultrasonic testing in addition to visual inspection shall be carried out for detection of internal flaws in the weld such as cracks, piping porosity inclusion, lack of fusion, incomplete penetration etc. Acceptance criteria shall be as per IS : 4260 or any other relevant IS Specification and as agreed to by the Engineer. Liquid Penetration Inspection: The liquid penetrant test shall be carried out for detection of surface defect in the weld, as per IS : 3658, in addition to visual inspection. The non-destructive testing of following welds be carried out using one of the method or methods described at (ii), (iii) and (iv) above, as may be agreed to by the Engineer. a) b) c) d) All transverse butt welds in tension flange 10 per cent of the length of longitudinal and transverse butt welds in tension flanges. 5 per cent of the length of longitudinal and transverse butt welds in compression flanges. All transverse butt welds in webs adjacent to tension flanges as specified by the Engineer.
(iv)
The particular length of welds in webs to be tested shall be agreed with the Engineer, in case of (b) or (c). Where specified by the Engineer, bearing stiffeners or bearing diaphragms adjacent to welds, flange plates adjacent to web/flange welds, plates at cruciform welds, plates in box girder construction adjacent to corner welds or other details shall be ultrasonically tested after fabrication. Any lamination, lamellar tearing or other defect found shall be recorded and reported to Engineer for his decision. Testing of Welding for Cast Steel: The testing of weld for cast steel shall be carried out as may be agreed to by the Engineer. tests: Stud Shear Connectors: Stud shear connectors shall be subjected to the following a) The fixing of studs after being welded in position shall be tested by striking the side of the head of the stud with a 2 kg hammer to the satisfaction of the Engineer.
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b)
The selected stud head stroked with 6 kg hammer shall be capable of lateral displacement of approximately 0.25 the height of the stud from its original position. The stud weld shall not show any sign of crack or lack of fusion.
The studs whose welds have failed the tests given in (a) and (b) shall be replaced. 1905.7.6. Inspection requirement: The fabricated member/component made out of rolled and built-up section shall be checked for compliance of the tolerances given in Table 1900-2. Inspection of member/components for compliance with tolerances, and the check for deviations shall be made over the full length. During checking, the inspection requirement shall be placed in such a manner that local surface irregularities do not influence the results. For plate, out-of-plane deviation shall be checked at right angle to the surface over the full area of plate. The relative cross-girder or cross frame deviation shall be checked over the middle third of length of the cross girder or frame between each pair of webs and for cantilever at the end of member. The web of rolled beam or channel section shall be checked for out-of-plane deviation in longitudinal direction equal to the depth of the section. During inspection, the component/member shall not have any load or external restraint. Inspection Stages: The inspection to be carried out for compliance of tolerances shall include but not be limited to the following stages: a) For completed parts, component/members on completion of fabrication and before any subsequent operation such as surface preparation, painting, transportation, erection. For webs of plate and box girder, longitudinal compression flange stiffeners in box girders and orthotropic decks and all web stiffeners at site joints, on completion of site joint. For cross girders and frames, cantilevers in orthotropic decks and other parts in which deviations have apparently increased on completion of site assembly.
b)
c)
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Where, on checking member/component for the deviations in respect of out-ofplane or out-of-straightness at right angles to the plate surface, and any other instances, exceed tolerance, the maximum deviation shall be measured and recorded. The recorded measurements shall be submitted to the Engineer who will determine whether the component/member may be accepted without rectification, with rectification or rejected. 1906. 1906.1. General Unless otherwise specified, all metal work shall be given approved shop coats as well as field coats of painting. The item of work shall include preparation of metal surfaces, application of protective covering and drying of the paint coatings and supply of all tools, scaffolding, labour and materials necessary. Coatings shall be applied only to dry surfaces and the coated surfaces shall not be exposed to rain or frost before they are dry. The coatings shall be applied to all surfaces excluding shear connectors and inner surfaces of fully sealed hollow sections. Care shall be taken during coating of adjacent surfaces to build up primer on the shear connectors. 1906.1.1. Types of paints (i) Ordinary Paints PAINTING
These include paints based on drying oils, alkyd resin, modified alkyd resin, phenolic varnish epoxy, etc. Alkyd resin paints for the protection of steel structures are based partly on natural oils and partly on synthetic resins. These paints shall be used for steel structures in atmospheres which are not too aggressive. Oil based paints can be used for steel structures in cases where the surface preparation cannot be ideal. Ordinary painting can generally be sub-divided into two groups: a) Primary Coats
This shall be applied immediately after the surface preparation and should have the properties of adhesion, corrosion inhibition and imperviousness to water and air. b) Finishing Coats These are applied over the primary coat and should have the properties of durability, abrasion resistance, aesthetic appearance and smooth finish.
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(ii)
Chemical Resistant Paints
The more highly corrosion resistant paints can be divided into two main groups: a) b) One pack paint (ready for use) Two pack paints (mixed before use)
The two pack paints shall be mixed together immediately before use since they are workable thereafter only for a restricted period of time and dry up as a result of a reaction between their components and yield hard tough films with resistance to abrasion. (iii) Vinyl Paints
These are based on polyvinyl resins such as polyvinyl-chloride (PVC) and polyvinyl-acetate, etc. Certain types of vinyl resin paints yield thick, relatively soft and rubber like coatings with good chemical resistance. They can be repainted without difficulty. (iv) Chlorinated Rubber Paints
These paints also have good chemical resistance. The main fields of applications shall be in aggressive environments. In general, chlorinated rubber paints do not have a high gloss. (v) Bituminous Paints
As a paint vehicle, bituminous is inferior, but because of the low price, this should be applied in greater thickness (upto several millimetres) and may be suitable for some situations. A significant advantage of bitumen paints is their impermeability to ingress of water. However, bituminous paints do not withstand effectively detrimental effects of oil. (vi) Epoxy Paints
These resin paints have good adherence to a well prepared sub-strata. They are mechanically strong and resistant to chemicals. A disadvantage of epoxy resin paints is that it can rapidly become dull when exposed to strong sunlight. These disadvantages do not, however, greatly influence their protective power. (vii) Polyurethane Paints
The chemical and mechanical behavior of polyurethane paint resembles those of epoxy paint very much. However, polyurethane paint retains its gloss for a longer period. Because of the high price of polyurethane paint, a combination of the two viz., polyurethane and epoxy paints may sometimes be used.
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(viii) Zinc Rich Paints Instead of introducing an inhibitive pigment into paint, metallic zinc can be used and such paints can provide cathodic protection to steel. 1906.1.2. Surfaces which are inaccessible for cleaning and painting after fabrication shall be painted as specified before being assembled for riveting. All rivets, bolts, nuts, washers etc., are to be thoroughly cleaned and dipped into boiling linseed oil conforming to IS : 77. All machined surfaces are to be well coated with a mixture of white lead conforming to IS : 34 and Mutton Tallow conforming to IS : 887. For site paintings, the whole of the steel work shall be given the second cover coat after final passing and after touching up the primer and cover coats, if damaged in transit. 1906.1.3. Choice of painting system The choice of suitable painting system is dependent on factors such as: Available application methods viz. brush, roller or spray Durability in a specific environment Availability of skilled manpower Cost/benefit etc.
It is therefore necessary to consult various manufacturers of paint and ascertain the above aspects while deciding on the appropriate choice of painting system. 1906.1.4. Quality of Paint:The paints which have been tested for the following qualities as per the specifications given in the relevant IS codes should only be used: Weight Test (weight per 10 litre of paint thoroughly mixed) Drying time Flexibility and Adhesion Consistency Dry thickness and rate of consumption
1906.1.5. Unless otherwise specified, all painting and protective coating work shall be done in accordance with IS : 1477 (Part 1).
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1906.2. Surface Preparation Steel surface to be painted either at the fabricating shop or at the site of work shall be prepared in a thorough manner with a view to ensuring complete removal of mill scale by one of the following processes as agreed to between the fabricator and the Engineer: a) b) c) Dry or wet grit/Sand blasting Pickling which should be restricted to single plates, bars and sections Flame cleaning
Primary coat shall be applied as soon as practicable after cleaning and in case of flame cleaning, primary coat shall be applies while the metal is still warm. All slag from welds shall be removed before painting. Surfaces shall be maintained dry and free from dirt and oil. Work out of doors in frosty or humid weather shall be avoided. 1906.3. Coatings Prime coat to be used shall conform to the specification of primers approved by the Engineer. Metal coatings shall be regarded as priming coatings. Primer shall be applied to the blast cleaned surface before any deterioration of the surface is visible. In any case, the surface shall receive one coat of primer within 4 hours of abrasive blast cleaning. All coats shall be compatible with each other. When metal coatings are used, the undercoat shall be compatible with the metal concerned. The undercoat and finishing coat shall preferably be from the same manufacturer. Successive coats of paints shall be of different shades or colours and each shall be allowed to dry thoroughly before the next is applied. Particular care shall be taken with the priming and painting of edges, corners, welds and rivets. Typical guidelines for epoxy based paints and the conventional painting system for bridge girders as given below may be complied with: a) Epoxy Based Painting i) Surface preparation: Remove oil/grease by use of petroleum hydrocarbon solution (IS : 1745) and Grit blasting to near white metal surface. ii) Paint system: 2 coats of epoxy zinc phosphate primer = 60 micron; Total 5 coats = 200 micron
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b) Conventional Painting System for areas where corrosion is not severe Priming Coat: One heavy coat or ready mixed paint, red lead primer conforming to IS : 102. or One coat of ready mixed zinc chrome primer conforming to IS : 104 followed by one coat of ready mixed red oxide zinc chrome primer conforming to IS : 2074. or Two coats of zinc chromates red oxide primer conforming to IS : 2074. Finishing Coats: Two cover coats of red oxide paint conforming to IS : 123 or any other approved paint shall be applied over the primer coat. One coat shall be applied paint before the fabricated steel work leaves the shop. After the steel work is erected at site, the second coat shall be given after touching up the primer and the cover coats if damaged in transit. (c) Conventional Painting System for areas where corrosion is severe Priming Coat: Two coats of ready mixed red lead primer conforming to IS : 102 or One coat of ready mixed zinc chrome primer conforming to IS : 104 followed by one coat of zinc chromate conforming oxide primer to IS : 2074. Finishing Coats: Two coats of aluminium paints conforming to IS : 2339 shall be applied over the primer coat. One coat shall be applied before the fabricated steel work leaves the shop. After the steel work is erected at site, the second coat shall be given after touching up the primer and the cover coats if damaged in transit. 1906.4. Painting in the Shop All fabricated steel shall be painted in the shops after inspection and acceptance with at least one priming coat, unless the exposed surfaces are subsequently to be cleaned at site or are metal coated. No primer shall be applied to galvanised surfaces.
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Shop contact surfaces, if specifically required to be painted, shall be brought together while the paint is still wet. Field contact surfaces and surfaces to be in contact with cement shall be painted with primer only. No paint shall be applied within 50 mm of designed location of field welds. Paint shall be completely dried before loading and transporting to site. Surface not in contact but inaccessible after shop assembly shall receive the fully specified protective treatment before assembly. Where surfaces are to be welded, the steel shall not be painted or metal coated within a suitable distance from any edges to be welded if the specified paint or metal coating would be harmful to welders or is expected to impair the quality of site welds. Exposed machined surfaces shall be adequately protected. 1906.5. Painting at Site Surfaces which will be inaccessible after site assembly shall receive the full specified protective treatment before assembly. Surfaces which will be in contact after site assembly shall receive a coat of paint (in addition to any shop priming) and shall be brought together white the paint is still wet. Damaged or deteriorated paint surfaces shall be first made good with the same type of coat as the shop coat. Where steel has received a metal coating in the shop, this coating shall be completed on site so as to be continuous over any welds, bolts and site rivets. Specified protective treatment shall be completed after erection. 1906.6. Methods of Application The methods of application of all paint coatings shall be in accordance with the manufacturers written recommendation and shall be as approved by the Engineer. Spray painting may be permitted provided it will not cause inconvenience to the public and is appropriate to the type of structure being coated. Area hard to gain access to for painting and areas shaded for spray application shall be coated first by brushing. Oil based red lead primers must be applied by brush only, taking care to work into all corners and crevices.
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The primer, intermediate and finishing coats shall all be applied so as to provide smooth coatings of uniform thickness. Wrinkled or blistered coatings or coatings with pinholes, sags, lumps or other blemishes shall not be accepted. Where the Engineer so directs, the coating shall be removed by abrasive blast cleaning and replaced at the Contractors expense. 1906.7. Guideline of Specifications for Protective Coating System in Different Environments Since the seriousness of the problem of corrosion depends upon atmospheric condition and vary enormously, there is no single protective system or method of application that is suitable for every situation. However, as a guide, broad recommendations are given in Table 1900-3. for various types of coatings in various environmental conditions which should be complied with. Approximate life to first maintenance is also indicated and can be used as a guide.
Signature of Bidder
i)
ii)
iii)
iv)
v)
vi) vii)
TABLE 1900-3: RECOMMEDATIONS FOR TYPES OF PROTECTIVE COATINGS System Environment Wire brush to remove all loose rust and Suitable for mild conditions where scale; 2 coats drying oil type primer; 1 appearance is of some importance and under coat alkyd type paint; 1 finishing where regular maintenance is intended. coat alkyd type. Total dry film thickness = This system may deteriorate to a marked extent if it is exposed to 150 m moderate aggressive atmospheric conditions for lengthy period Wire brush to remove all loose rust and Similar to (I) but where appearance is scale; 2 coats drying oil type primer; 2 not very important provides longer life under coats micaceous iron oxide (MXO) in mild condition. Will provide upto 5 pigmented phenolic modified drying oil. years life to first maintenance in polluted inland environment Total dry film thickness = 170 m Blast clean the surface; 2 coats of quick Compared to (I), this would provide a drying primer; undercoat alkyd type paint; longer life in mild conditions and could 1 finishing coat alkyd type. Total dry film be used in less mild situation e.g. inland polluted, where maintenance thickness : 130 150 m could easily be carried out at regular intervals Blast clean the surface; 2 coats of drying Suitable for general structural steel type oil primer; 1 undercoat micaceous work exposed to ordinary polluted iron oxide pigmented drying oil type inland environments where appearance paint. Total dry film thickness : 165 190 is not of primary importance. m Blast clean the surface; 2 coats of metallic Suitable for structures in reasonably lead pigmented chlorinated rubber primer, aggressive conditions e.g near the coast. 1 undercoat of high build chlorinated Will provide long-term protection than rubber; 1 finishing coat of chlorinated (iv) in non-coastal situations. Also for aggressive interior rubber. Total dry film thickness : 200 m suitable situations such as industrial areas. Blast clean the surface; 350 450 m Suitable for sea water splash zones or for conditions of occurrence of frequent thickness. Coal tar epoxy. salt sprays. Pickle; hot dip galvanised (Zinc). Total Suitable for steel work in reasonably mild conditions Life of 15-20 years thickness : 85 m before first maintenance could be expected in many situations Grit blast, hot dip galvanised. (Zinc). Total thickness = 140 m Grit blast; 1 coat of sprayed zinc/aluminum followed by suitable sealer Total thickness = 150 m Provides a longer life than (vii) because of thicker zinc coating Expected to provide long term protection approx 1520 years in aggressive atmosphere
viii) ix)
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1907. TESTS AND STANDARDS OF ACCEPTANCE The materials shall be tested in accordance with relevant IS specifications and necessary test certificates shall be furnished. Additional tests, if required, shall be got carried out by the Contractor at his own cost. The fabrication, furnishing, erecting, painting of structural steel work shall be in accordance with these specifications and shall be checked and accepted by the Engineer. 1908. MEASUREMENTS FOR PAYMENT The measurements of this item shall be in tonnes based on the net weight of metal in the fabricated structure computed on the basis of nominal weight of materials. The weight of rolled and cast steel and cast iron shall be determined from the dimensions shown on the drawings on the following basis: Rolled or cast steel : 7.84 x 10-3 kg/cu. cm. Cast Iron : 7.21 x 10-3 kg/cu. cm.
Weight of structural sections shall be nominal weight Weight of castings shall be computed from the dimensions shown on the drawings with an addition of 5 per cent for files and over-runs. Weight of weld fillets and the weight of protective coatings shall not be included. Weight of rivet heads shall be computed by taking the weight of 100 snap heads as given in Table 1900-4. When specially agreed upon, allowance for snap heads may be taken as a flat percentage of the total weight. This percentage may be taken as 3 per cent or modified by mutual agreement.
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TABLE 1900 4: WEIGHT OF RIVET HEADS Dia of Rivet as manufactured mm 12 14 16 18 20 22 24 27 30 33 Weight of 100 snap heads kg 1.3 2.1 3.4 4.45 6.1 8.1 10.5 15.0 20.5 27.2
The Contractor shall supply detailed calculation sheets for the weight of the metal in the fabricated structure. No additions shall be made for the weight of protective coating or weld fillets. Where computed weight forms the basis for payment, the weight shall be calculated for exact cut sizes of members used in the structure, deductions being made for all cuts, except for rivet holes. Additions shall be made for the rivet heads as mentioned above. When specially agreed upon, the basis for payment may be the bridge weight complete, according to specifications included in special provisions of the Contract. 1909. RATE The contract unit rate for the completed structural steel work shall include the cost of all materials, labour, tools, plant and equipment required for fabrication, connections, oiling, painting, temporary erection, inspection, tests and complete final erection as shown on the drawings and as specified in these Specifications.
Signature of Bidder
2501. DESCRIPTION River training and protection work shall include construction of guide bunds, guide walls, bank protection, flooring and approach embankment protection as required for ensuring safety of the bridge structure and its approaches against damage by flood/flowing water. Construction of various components shall conform to IRC : 89 and these specifications or as directed by the Engineer. 2502. GUIDE BUND 2502.1. This work shall consist of construction of embankment of guide bund and provision of pitching/rivetment on slopes, apron, toe protection, curtain walls etc. as indicated on the drawing in accordance with these specifications or as approved by the Engineer. The provisions given hereunder are applicable only to guide bunds for bridges across alluvial rivers. Guide bunds for bridges across submontane rivers shall call for supplemental specifications. 2502.2. The alignment and layout of guide bund shall be as indicated on the drawing or as approved by the Engineer. The construction of embankment for guide bund shall conform to provisions of Section 300 of these Specifications. Pitching, filter underneath pitching and turfing, apron, toe protection, curtain walls, etc., shall be as per these specifications. 2502.3. Guide bunds shall generally be made of locally available materials from the river bed preferably cohesionless materials. Trial pits shall be taken in borrow holes to examine suitability of soil for construction and also to decide the types of earth moving machinery to be arranged. The borrow pits should be sufficiently away from the location of the launching apron. No borrow pits should be dug on the river side of the guide bunds. Construction of guide bund shall be taken in hand alongwith the construction of the bridge. Every effort shall be made to complete the work of the guide bund in one working season. Where there is any doubt about completion of the whole guide bund within one working season, suitable measures shall be planned and executed for protection of completed work. In such cases the construction of guide bund shall be started from abutment towards upstream. 2502.4. Construction of apron and pitching of the guide bunds shall generally conform to clause 2503 and 2504 of these Specifications. Sufficient length of pit along the guide bund shall be ready within one to two months of commencement of work so that the placing of stones in the apron and in the slope pitching can be commenced. As a guideline, earthwork should be completed within 80 per cent of working season and about 70 per cent working season shall be available for laying apron laying apron and pitching. No portion of guide bund should be left below HFL before the onset of
Signature of Bidder
monsoon. Bottom of apron pit shall be as low as permitted by sub-soil water/lowest water level. Sufficient labour and appropriate earth moving machinery and trained staff shall be deployed in construction. 2502.5. The Contractor shall furnish his planning for approval of the Engineer regarding transport of stones from the quarries to the site of work taking into account the quantities of stone required to be transported every day, train/truck, etc., deployed, available ferry or boats and labour available for loading and unloading and for laying within the time frame for construction of guide bund. Adequate reserve of stones should be maintained for major works as decided by the Engineer. Reserve stones shall be stacked far away from the main channel of the river. 2502.6. Where the alignment of guide bund or the approach embankment crosses a branch channel of the river, the branch channel may be either diverted to the main channel of the river with the help of spurs, etc. or closed by a properly designed closing dyke or closure bund taking up construction of guide bund. 2503. APRON 2503.1. General This work shall consist of laying boulders directly or in wire crates on the bed of rivers for protection against scour. Where the required size of boulders are not available economically, cement concrete blocks of equivalent weight shall be used. The grade of concrete shall be M15 nominal mix. (This holds good for pitching on the slopes and flooring also). Cement concrete blocks shall be preferred where practicable. The stones used in apron shall be sound, hard, durable and fairly regular in shape. Stone subject to marked deterioration by water or weather shall not be used. Quarry stones are preferable to round boulders as the latter roll off easily. Angular stones fit into each other better and have good interlocking characteristics. Where the required size stones are not economically available, cement concrete blocks in M15 grade conforming to Section 1700 or stones in wire crates in combination may be used in place of isolated stones of equivalent weight. Cement concrete blocks will be preferred, wherever practicable. 2503.2. Laying Boulder Apron The size of stone conform to clause 5.3.7.2. of IRC : 89. The size of stone shall be as large as possible. In no case any fragment shall weigh less than 40 kg. The specific gravity of stones shall be as high as possible and it
Signature of Bidder
shall not be less than 2.65. To ensure regular and orderly disposition of the full intended quantity of stone in the apron, template cross walls in dry masonry shall be built about a metre thick and to the full height of the specified thickness of the apron at intervals of 30 metres all along the length and width of the apron. Within these walls, the stones then shall be hand packed. The surface on which the apron is to be laid shall be levelled and prepared for the length and width as shown on the drawings. In case the surface on which apron is to be laid below the low water level, the ground level may be raised upto low water level by dumping earth and the apron laid thereon. The quantity of stone required in the apron shall be re-worked out by taking the toe of pitching at higher level. 2403.3. Laying Wire Crates and Mattresses in the Apron Wire crates shall be made from hot dipped galvanized mild steel wire of diameter not less than 4 mm in annealed condition having tensile strength of 300-450 MPa conforming to IS : 280. The galvanizing coating shall be heavy coating for soft condition conforming to IS : 4826. The mesh of the crate shall not be more than 150 mm. Wire crates for shallow or accessible situations shall be 3 metre x 1.5 metre x 1.25 metre in size. Where these have to be deposited and there is a chance of overturning, the crate shall be divided into 1.5 metre compartments by cross netting. For deep or inaccessible situations, wire crates can be made smaller subject to the approval of the Engineer. Wire crates built in-situ, shall not be larger than 7.5 metres x 3 metres x 0.6 metre, nor smaller than 2 metres x 1 metre x 0.3 metre. Sides of large crates shall be securely stayed at intervals not more than 1.50 metres to prevent bulging. The netting shall be made by fixing a row of spikes on a beam at a spacing equal to the mesh. The beam must be a little longer than the width of netting required. The wire is to be cut to lengths about three times the length of the net required. Each piece shall be bent at the middle around one of the spikes and the weaving commenced from one corner. A double twist shall be given at each intersection. This twisting shall be carefully done by means of a strong iron bar, five and half turns being given to the bar at each splice. The bottom and two ends of the crate or mattress shall be made at one time. The other two sides shall be made separately and shall be secured to the bottom and the ends
Signature of Bidder
by twisting adjacent wires together. The top shall be made separately and shall be fixed in the same manner as the sides after the crates or mattress have been filled. Wherever possible, crates shall be placed in position before filling with boulders. The crates shall be filled by carefully hand-packing the boulders as tightly as possible and not by merely throwing in stones or boulders. For laying of wire crates in aprons of bridges, two situations arises: i) ii) 2504. Where the crates are to be laid in deep water and have to be dumped and then joined together. Where depth of water is low or dry bed is available. In such cases, the crates can be laid at site.
PITCHING/REVETMENT ON SLOPES
2504.1. Description This work shall consist of covering the slopes of guide bunds, training works and road embankments with stone, boulders, cement concrete blocks or stones in wire crates over a layer of granular material called filter. While river side slopes are given this protection against river action, the rear slopes, not subjected to direct attack of the river, may be protected against ordinary wave splashing by 0.30.6 metre thick cover of clayey or silty earth and turfed. 2504.2 Pitching/Filter media 2504.2.1. Pitching: The pitching shall be provided as indicated in the drawings. The thickness and the shape of stone pitching shall be shown on the drawing. The stone shall be sound, hard, durable and fairly regular in shape. Quarry stone should be used. Round boulders shall not be allowed. The stones subject to marked deterioration by water or weather shall not be accepted. The size and weight of stone shall conform to clause 5.3.5.1 of IRC : 89. No stone, weighing less than 40 kg shall, however, be used. The sizes of spalls shall be a minimum of 25 mm and shall be suitable to fill the voids in the pitching. Where the required size stones are not economically available, cement concrete blocks in M15 grade conforming to Section 1700 or stones in wire crates may be used in place of isolated stones of equivalent weight. Cement concrete blocks will be preferred wherever practicable. Use of geosynthetics has been dealt with in Section 700. 2504.2.2. Filter media: The material for the filter shall consist of sand, gravel, stone or coarse sand. To prevent escape of the embankment material through the voids of
Signature of Bidder
the stone pitching/cement concrete blocks as well as to allow free movement of water without creating any uplift head on the pitching, one or more layers of graded materials, commonly known as a filter medium, shall be provided underneath the pitching. The gradation of the filter material shall satisfy the following requirements: Provision of a suitably designed filter is necessary under the slope pitching to prevent the escape of underlaying embankment material through the voids of stone pitching/cement concrete blocks when subjected to the attack of flowing water and wave action, etc. In order to achieve this requirement, the filter may be provided in one or more layers satisfying the following criteria: D 15 (Filter) D 85 (Base) D 15 (Filter) D 15 (Base) D 50 (Filter) D 50 (Base) Notes : 1. <5
4<
< 20
< 25
Filter design may not be required if embankment consists of CH or Ch soils with liquid limit greater than 30, resistant to surface erosion. In this case, if a layer of material is used as bedding for pitching, it shall be well graded and its D 85 size shall be at least twice the maximum void size in pitching. In the foregoing, D 15 means the size of that sieve which allows 15 per cent by weight of the filter material to pass through it and similar is the meaning of D 50 and D 85. If more than one filter layer is required, the same requirement as above shall be followed for each layer. The fine filter shall be considered as base material for selection of coarser filter. The filter shall be compacted to a firm condition. The thickness of filter is generally of the order of 200 mm to 300 mm. Where filter is provided in two layers, thickness of each shall be 150 mm
2.
3.
4.
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2504.3
Construction Operations
Before laying the pitching, the sides of banks shall be trimmed to the required slope and profiles put up by means of lines and pegs at intervals of 3 metres to ensure regular straight work and a uniform slope throughout. Depressions shall be filled and thoroughly compacted. The filter granular material shall be laid over the prepared base and suitably compacted to the thickness specified on the drawings. The lowest course of pitching shall be started from the toe wall and built up in courses upwards. The toe wall shall be in dry rubble masonry (uncoursed) conforming to Clause 1405.3, in case of dry rubble pitching and shall be in nominal mix cement concrete (M15) conforming to Clause 1704.3 in case of cement concrete block pitching. The stone pitching shall commence in a trench below the toe of the slope. Stone shall be placed by derrick or by hand to the required length, thickness and depth conforming to the drawings. Stones shall be set normal to the slope, and placed so that the largest dimension is perpendicular to the face of the slope, unless such dimension is greater than the specified thickness of pitching. The largest stones shall be placed in he bottom courses and for use as headers for subsequent courses. In hand placed pitching, the stone of flat stratified nature should be placed with the principle bedding plane normal to the slope. The pattern of laying shall be such that the joints are broken and voids are minimum by packing with spalls, wherever necessary, and the top surface is as smooth as possible. When full depth of pitching can be formed with a single stone, the stones shall be laid breaking joints and all interstices between adjacent stones shall be filled in with spalls of the proper size and wedged in with hammers to ensured tight packing. When two or more layers of stones must be laid to obtain the design thickness of pitching, dry masonry shall be used and stones shall be well bonded. To ensure regular and orderly disposition of the full intended quantity of stone as shown, template cross walls in dry masonry shall be built about a metre wide and to the full height of the specified thickness at suitable intervals and all along the length and width of the pitching. Within these walls the stones shall be hand packed as specified. 2404. Toe Protection In conformity with clause 5.3.7. of IRC : 89, a toe wall shall be provided at the junction of slope pitching and launching apron of a guide bund so as to protect the slope pitching from falling even when the apron is not laid at low water level. The toe wall shall be in dry rubble masonry (uncoursed) conforming to Clause 1405.3 in case of dry
Signature of Bidder
rubble pitching or pitching/revetment with stones in wire crates and in nominal mix cement concrete (M15) conforming to Clause 1704.3 in case cement concrete blocks have been used in pitching. For protection of toes of bank slopes terminating either in short aprons at bed levels or anchored in flooring/rocky bed, the provisions of clause 8.2.2. of IRC : 89 may be complied with. The relevant specifications of the protective works for individual components will be followed. 2505. RUBBLE STONE/CEMENT CONCRETE BLOCK FLOORING OVER CEMENT CONCRETE BEDDING 2505.1. This work shall consist of construction rubble stone/c.c. block flooring laid over a cement (M15) bedding. The floor protection will comprise rigid flooring stated above with curtain walls and flexible apron. 2505.2. Construction Operations Excavations for laying the bedding and floor protection works shall be carried out as per specifications under proper supervision. Before laying the foundation and protection walls, the excavated trenches shall be thoroughly inspected by the Engineer-in Charge to ensure that: a) b) c) There are no loose pockets and unfilled depressions left in the trench. The soil at the founding level is properly compacted to the true lines and level so as to have an even bedding. All concrete and other elements are laid in dry bed.
Cement concrete nominal mix (grade M 15) of 300 mm thickness shall then be laid in accordance with provisions given in Section 1700 except that the surface of the concrete shall not be given a smooth finish. The paving work shall be embedded in green concrete. Flooring shall consist of 150 mm thick flat stone/cement concrete blocks (Nominal mix Grade M 15 conforming to Section 1700). It shall be bedded on a layer of cement mortar (1:3) prepared to Clause 1304. Spalls shall be used to fill in the voids. The joints shall then be filled with cement mortar and finished neat. The stone shall break joints and the joints shall not exceed 20 mm in thickness. Spacing of joints may be 20 m or so. The top of flooring shall be kept to 300 mm below the lowest bed level. 2506. DRY RUBBLE FLOORING
This work shall consist of construction dry rubble flooring at cross drainage works for relatively less important works. The base for the flooring shall be prepared to the specified levels and slopes and
Signature of Bidder
compacted suitably with hand rammers or other means to have an even bedding. The thickness of flooring shall be made with one stone only. The stones shall then be laid closely on the prepared base in one or more layers as specified and the bond used shall be as specified by the Engineer. 2507. CURTAIN WALL AND FLEXIBLE APRON 2507.1. Curtain Wall The rigid flooring shall be enclosed by curtain walls (tied to the wing walls) with a minimum depth below floor level of 2 m on upstream side and 2.5 m on downstream side. The curtain wall will be in cement concrete M 15/stone masonry in cement mortar 1 : 3. The rigid flooring shall be continued over the top width of curtain wall. 2507.2. Flexible Apron Flexible apron 1 m thick comprising loose stone boulders (weighing not less than 40 kg) shall be provided beyond curtain walls for a minimum distance of 3 m on upstream side and 6 m on downstream side. The work of floor protection shall be simultaneously completed alongwith the work on bridge foundations. 2508. TESTS AND STANDARDS OF ACCEPTANCE
The materials shall be tested in accordance with these Specifications and shall meet the prescribed criteria. The work shall conform to these Specifications and shall meet the prescribed standards of acceptance. 2509. MEASUREMENTS FOR PPAYMENT
The protection works shall be measured as set forth below. If directed by the Engineer for measurement, the materials may have to be stacked at site before laying and nothing extra will be paid to the Contractor for this stacking. The earth work in construction of embankment for guide bund shall be measured in cubic metres unless otherwise specified. The boulders/cement concrete blocks and wire crates in apron shall be measured in cubic metres. The filter and stone pitching shall be measured separately in cubic metres unless otherwise specified. Rubble stone/cement concrete blocks, flooring and cement concrete bedding shall
Signature of Bidder
be measured in cubic metres for each class of material. Preparation of base for laying the flooring shall be deemed incidental to the work. For laying apron, excavation upto an average depth of 150 mm shall be deemed to be included in the main item and shall not be measured separately unless otherwise specified. Excavation more than 150 mm shall be measured in cubic metres as given in Clause 304. 2510. RATE The contract unit rate for the construction of embankment for guide bund shall cover the cost of all materials including transportation, laying, compacting, all labour, tools, equipment, sampling and testing, supervision and all incidentals necessary for completing the work according to these specifications. The contract unit rate for one cubic metre of finished work of apron shall include the cost of all material, labour, tools and plant for completing the work according to above specifications. Excavation upto an average depth of 150 mm shall also be deemed to be included in the rate as dressing of the bed. Excavation beyond this depth shall be paid for separately unless other specified. The contract unit rate for one cubic metre of filter or stone/cement concrete block pitching on slopes shall include the cost of preparing the bases, putting to the profiles, laying and compacting the filter and stone pitching of dry rubble/cement concrete block rivetment for embankment slopes to the specified thickness, lines, curves, slopes and levels and all labour and materials as well as tools and plant required for the work. The contract unit rate for rubble stone/cement concrete block flooring shall include the cost of all material, labour and tools and plant for completing the work as per these specifications.
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(N) Upto 50 51 to 100

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(b) (c) (d) (e)

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0.1 Kg 0.15 Kg 0.20 Kg 0.25 Kg 0.30 Kg 0.35 Kg

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SN 1250 & SN 2500 SN 5000 SN 10000 D.6.1.24 Measurement

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Hot dip galvanised steel mantle

Mechanical steel couplings and/or Lay-up joints

CONNECTION WITH EXISTING TRUNKS

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IMPORTANT CONSIDERATIONS, INSPECTION/PRECAUTIONS FOR DIFFERENT TYPES OF PILES

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Variation of level of top of piles

TESTS AND STANDARDS OF ACCEPTANCE

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a) PCC members b) RCC members c) PSC members